The Institue of Quarrying Australia has revealed the members of its new ambassador program.
Switzerland
INNOVATION IS CRITICAL Eltirus founder Steve Franklin explains why innovative thinking is critical in quarrying.
CREATING VALUE
Terex Washing Systems’ new bespoke solution is driving value for Ghelma in
CDE’s
Steve
How do you turn a 25-tonne screener into a miniature?
14 Better together
A partnership enables quarries to access better equipment solutions.
16 A valuable fleet tool
Komatsu’s myFleet platform is designed for fleet management within the quarry.
20 More than just pumps
Toolkwip Pumps provides quarries with the much more than just pumps.
22 Customised solutions
Why one-size-fits-all approaches can fail in wet sand processing.
24 Hallett Group discovers Volvo Site Solutions benefit
Quarries across Australia have the chance to contribute to the sand industry.
The strategic partnership has enhanced efficiency.
Suitable solutions
Precisionscreen’s sand-washing range is made for Australian conditions.
XMOR lasts the distance
Rob Matthews details his experience using the XMOR Bucket.
European solution to
Magotteaux’s vertical shaft impact is providing an alternative for sand mining.
Handle the pressure
Metso’s high-pressure grinding rolls are helping quarries deliver high-quality sand.
44 Rethinking granite
A family-owned quarry is using innovative practices to meet sand demands.
46 Future focused
VRX Silica aims to pioneer a new way forward with its silica sand deposits.
48 Marking new territory
Territory Sands is backing itself to become one of Australia’s key frac sand quarries.
KEEPING SAND FLOWING
Christmas is just around the corner, and it looks like we’re in for a hot summer. Thousands will soon be heading down to the beach to take advantage of the refreshing water and warm sand.
It will also, unfailingly, lead to plenty of cleaning, as sand has a habit of getting everywhere. Except, it would seem, into concrete.
High-quality sand used for manufacturing the vital construction material is becoming harder to come by as environmental regulations tighten worldwide.
Quarries play an important part of sand supply, providing crucial sand to fuel the infrastructure megaprojects.
Some states, like Victoria, understand the importance of ensuring supply. Earlier this year, the State Government approved the first new sand quarry close to Melbourne in more than 20 years. Estimated to hold more than 13 million tonnes of sand, the site at Lang Lang will help ensure supply keeps up with the demand of the Big Build and residential construction across Victoria –keeping material prices low.
The Government also established, the Resources Victoria Approvals Coordination unit in 2023, which supported the Lang Lang quarry to obtain planning permission through the Government’s Development Facilitation Program.
Quarries can also take advantage of the situation through manufactured sand, turning byproducts into the valuable material.
This edition of Quarry highlights some of the key innovations in this sector, showcasing the crushing equipment creating manufactured sands.
Not only does this have an economic benefit, but it also has a sustainability one, as some manufactured sands can even replace the amount of cement needed.
The next edition of the magazine will be our annual Industry Leaders issue, where we explore the key lessons from 2024, and look ahead to the future.
If you would like to get involved with this, please get in touch.
William Arnott Editor
Published by:
379 Docklands Drive
Melbourne VIC 3008
T: 03 9690 8766
www.primecreativemedia.com.au
Chief Executive Officer
John Murphy john.murphy@primecreative.com.au
Managing Editor
Paul Hayes paul.hayes@primecreative.com.au
Editor
William Arnott william.arnott@primecreative.com.au
Assistant Editor Adam Daunt adam.daunt@primecreative.com.au
As we close out 2024, I’m proud to reflect on what has been a remarkable year of progress and achievement for the Institute of Quarrying Australia.
Our membership has grown by 3.62 per cent to reach 1,686 members. Particularly encouraging is the continued growth in female representation, now comprising 11 per cent of our total membership – a testament to the impact of our Women in Quarrying (WIQ) network.
Education remains central to our mission, with 57 professional development courses delivered across the country this year. Our branch network has been exceptionally active, hosting 66 events that attracted over 2400 participants – a noteworthy 20 per cent increase from the previous year. This growth reflects both the quality of our offerings and the industry’s commitment to continuous learning and networking.
The appointment of Jane Schmitt as CEO in May has brought fresh perspective and energy to our organisation. Under her leadership, we are making significant strides in implementing our Strategic Plan 2023-26, particularly in aligning our educational offerings with updated competency frameworks.
In August-September, we conducted a comprehensive member survey to better understand your needs and ensure our services remain aligned with industry requirements. This valuable feedback is helping us refine our member offerings and services.
Our national conference from 15–17 October in Adelaide was undoubtedly a highlight, setting new benchmarks with 635 delegates, 77 exhibitors, and 52 speakers. Beyond these
impressive numbers, the conference introduced an innovative student engagement initiative, welcoming 60 students aged 14–18 to explore our industry.
Looking ahead to 2025, we have several exciting initiatives in development, including a public education campaign to communicate the essential role quarries play in building Australia’s infrastructure and communities, and our new IQA Ambassador Programme. Our focus on digital transformation continues with the launch of our IQA Education Hub in July this year and a new website in development in 2025.
These developments, combined with our expanding networking events programme, will provide even more value to our membership in the coming year.
The announcement of our 2026 national conference on the Gold Coast gives us another milestone to work towards. Until then, we’ll continue building on the momentum of 2024, promoting innovation, sustainability, and professional excellence across our industry.
As we approach the festive season, I want to thank our dedicated Board, branch committees, sponsors, and members for their continued support. I wish you all a safe and joyous holiday season with your families and loved ones, and look forward to working together for an even more successful 2025.
Michael Close President Institute of Quarrying
Australia
EDUCATION REMAINS CENTRAL TO OUR MISSION, WITH 57 PROFESSIONAL DEVELOPMENT COURSES DELIVERED ACROSS THE COUNTRY THIS YEAR.
The IQA’s Strategic Plan 2023 to 2026 embodies the following vision, values and strategic priorities:
Vision:
Thriving communities supported by a sustainable industry
Operational Priorities:
• Deepen industry participation
• Sustainable revenue streams
• Highly capable team
• Technological innovation
• Effective engagement
• Great governance
Strategic Priorities:
• Support industry participants with compliance and regulation
• Build a diverse and skilled industry workforce
• Foster strong industry connectivity
IQA Contacts:
Phone: 02 9484 0577
Email: admin@quarry.com.au
Chief Executive Officer
Jane Schmitt
President
Michael Close
Company Secretary
David Cowie
For all education, member and branch enquires please email: admin@quarry.com.au.
GEOLOGY
IS GEOLOGICAL UNCERTAINTY INCREASING YOUR RISK?
Eltirus Exploration, Geological Modelling, and Resource Assessment services.
We work with quarry operators to explore, model, and assess your resource, increasing certainty of operation and reducing risk. Our experienced geological team help identify gaps in understanding, create exploration programs, and manage the program for you. Whether it be field mapping or blast hole, RC, aircore or diamond drilling, we not only help you explore and assess your deposit, but also ensure outputs are accessible through the use of world-class geological modelling software that provides you with interactive models that truly make a difference on the ground and in the field.
INDUSTRY PROGRAM
MEET THE AMBASSADORS
The Institute of Quarrying Australia has launched its new ambassador program for 2025. Quarry looks at who is involved and what the program will achieve.
The Institute of Quarrying Australia (IQA) selected 26 of the industry’s most respected leaders to champion its mission and growth in 2025.
The diverse group of ambassadors will play an essential role in strengthening the IQA community and enhancing engagement with new and existing members.
The IQA has unveiled the list of ambassadors in Quarry ahead of the program getting underway in 2025 for the first time.
“These ambassadors will play a vital role in helping enhance our IQA community as we look to grow it in the coming years,” IQA chief executive officer Jane Schmitt said.
“We want to ensure our members are getting the most value from their memberships, and the ambassadors will help ensure our offerings are tailored to our community’s needs to succeed in their roles.”
The new program is part of a targeted approach from the IQA to increase awareness about the industry, growing its membership base, and improving the IQA’s offering to members through direct industry feedback.
IQA initiatives.
IQA
Images:
To be selected for the program, nominees had to be current and active members of the IQA in good standing and passionate about the IQA’s mission.
Together, the group will help promote the IQA’s events including its education and networking opportunities. They will also serve as a point of contact for new,
They will also be on hand to support their local branches and sub-branches in hosting meet-ups or virtual events to engage their community.
They will facilitate communication between the organisation and members, helping to share feedback and insights from the industry, associated industries, and branch committees. These industry insights will improve IQA activities and processes.
“We’re thrilled to announce the IQA Ambassador Program for 2025 with a group of industry leaders who are passionate about the IQA’s purpose and mission,” Schmitt said.
“We know that the IQA community is incredibly knowledgeable and passionate
about their field, and we believe this program will only add to the sector’s vibrancy.
“Congratulations to all the ambassadors who were selected for this role. It is a testament to their skills and reputation within the industry that they were nominated for the inaugural program, and we look forward to seeing what we can achieve together in 2025.” •
Carly Monaghan is an IQA Ambassador for South Australia.
SURVEY SHOWS SUPPORT FOR PUBLIC EDUCATION
The Institute of Quarrying Australia (IQA) has revealed the latest results from its member survey, which includes education, events, and networking on the agenda.
The IQA survey was designed to allow the organisation to engage members in 2025 and beyond. The survey received 310 responses from a pool of 1618 members, which delivered an 18.4 per cent response rate, exceeding the benchmark of 15 per cent.
“The positive response reflects our members’ dedication to the IQA community and its activities. These results will provide essential insights to guide our future initiatives and improvements,” said Jane Schmitt, chief executive officer of the Institute of Quarrying Australia.
IQA members aged between 45 and 54 represented the majority of respondents (30.1 per cent), closely followed by members aged between 55 and 64 (29.1 per cent). Younger members aged between 35 and 44 rounded out the top three age groups, with 15.9 percent of respondents.
Most respondents identified as male (88.4 per cent), with female members accounting for 10.7 per
cent of respondents, mirroring the current gender distribution within the quarrying sector.
The key member insights from the survey showed that the IQA had many long-term members, with 39 per cent of respondents being part of the IQA for over a decade. However, only 24 per cent of members are involved in IQA committees.
“This suggests there is a significant opportunity for increased engagement with our members and getting the benefit of their experience and skills in our committees. We’re committed to exploring new ways to connect with members to boost their engagement and overall satisfaction,” Schmitt said.
The survey identified three key areas of focus for members: events and networking (primary focus), followed by education and training (38 per cent) and continuing professional development (9 per cent).
Members have shown strong support for IQA’s call for a comprehensive public education campaign, with over 75 per cent of respondents rating this initiative as “extremely important”.
The endorsement reinforces IQA’s position that communities
need a better understanding of quarrying’s vital role.
“The survey results clearly show our members share our vision. We want to help communities understand the essential role of quarries - from their strategic locations to rehabilitation, from local job creation to providing vital construction materials. There is a need for education to reach schools and wider communities, highlighting quarries’ essential contribution to local infrastructure and environmental management practises,” Schmitt said.
Improving public understanding could help address workforce challenges, she noted.
“Through enhanced community engagement, we aim to showcase quarrying
as an essential industry with rewarding career pathways.
This clear support from our members provides an excellent foundation for developing and launching a public awareness campaign,” Schmitt said.
Schmitt highlighted key priorities for IQA in the future.
“We see a clear desire for promoting quarries’ role within communities and among stakeholders. There is also strong interest in expanding our networking events and education opportunities,” she said.
“These insights will help us create programmes that ensure members receive maximum value from their IQA membership whilst strengthening our industry’s position in the community.” •
The Institute of Quarry Australia has released its member survey results.
PRODUCT FOCUS
TRAMP METAL DETECTOR AVAILABLE IN AUSTRALIA
The Metcorr 117C Tramp Metal Detector is available for quarry operators from Conductix-Wampfler.
The Metcorr 117C Tramp Metal Detector can be used with basalt, limestone, coal, gold ore, bauxite, nickel and more. It helps detect ferrous and non-ferrous metal objects in conveyed material, preventing damage and excessive wear on processing equipment. Operating with two identical coil sets that generate a magnetic field, which in turn excites eddy currents in the targeted metal objects, detection takes place when the signal level exceeds the detection limit. Depending on the specific conveyed material and what the client is looking to detect, all settings and sensitivities can be controlled using the supplied electronics cabinet to ensure the desired detection level is achieved every time.
The Metcorr 117C Tramp Metal Detector is a rugged detection system built for harsh conditions with minimal maintenance and servicing. The unit also has an upper swing bar to ensure coil protection redundancy is built into your detection system. An optional fibreglass coil mounting set is also available to achieve optimal mounting.
Conductix-Wampfler maintains offices around Australia in Melbourne, Sydney, Perth and Brisbane, which can support customers in their applications.
For more information, visit conductix.com.au/en
To submit
NEW PINNACLE IN THE HUNTER VALLEY
Pinnacle Hire has officially launched its latest store to support customers in the Hunter Valley.
The new branch, located in Rutherford, New South Wales, will support customers in the Hunter Valley region’s heavy industries, including quarrying, mining, and civil construction.
“We are excited to announce that our team has opened a new branch in Rutherford, NSW, serving the civil construction and mining industry in the Hunter Valley,” the company said.
“As your trusted partner for dewatering solutions, we are committed to delivering top-notch services to support your dewatering projects. Our experienced team is ready to provide expert advice and assistance with all your dewatering needs.”
Pinnacle Hire is known for its water management solutions, including tank maintenance and dewatering projects.
Its product portfolio includes a wide range of pumps, including submersible pumps.
Pinnacle Hire stocks 4-12” skid-mounted pumps, 4-6” trailer-mounted pumps, sludge handling pumps, submersible pumps, and fuel cells for general pumping and water transfer solutions. The company also stocks high-head and high-flow pump sets, turnkey bore packages, installation, and engineered solutions for pit and mine dewatering.
For clients needing generators or power distribution solutions, Pinnacle Hire has a range of options, including -1250 kilo-volt-amperes silenced diesel generators, hybrid generators, and power distribution systems.
The company’s range of sediment tanks, coagulants, flocculants, pH adjustment systems, sediment control, hydrocarbon remediation, and turnkey solutions can handle any water and wastewater treatment issues customers face in Australia’s heavy industries.
For dam and pond maintenance or remediation, Pinnacle Hire provides remote-operated dredges, dredging and desludging services, and specialised equipment for sludge removal. It can also tackle bulk water management with a customised solution using its range of bulk water tanks, standpipes, and remote on-and-off systems.
These are all complemented by Pinnacle Hire’s unique technology offerings, including Eagle Eye remote control and monitoring systems, which support custom-packaged solutions for customers’ specific project needs. It also provides turnkey solutions, including dry and wet hire of dewatering equipment, installation and commissioning, maintenance and repair services, and operator training and support.
The Hunter Valley site joins Pinnacle Hire’s extensive Australian network, which includes facilities in Western Australia, Victoria, NSW, Queensland, the Northern Territory, and Tasmania.
For more information, visit pinnaclehire.com.au
Image: Pinnacle Hire
Image: Conductix-Wampfler
ENGINEERED FOR PF FORMATION
Our sand and gravel washing plants are used by many of the world’s leading construction materials producers to:
• Maximise resource yield • Maximise equipment life
• Minimise waste • Maximise return on investment
Whether you need an upgrade or a proven turnkey solution, we will co-create with you to deliver a solution that will add maximum value to your business.
“CDE has supported us in providing the most optimal solution, one we’re proud to have invested in and that’s making a real difference to the business.”
Luke Graham, Managing Director at PF Formation
TURNING WASTE INTO VALUE
Terex Washing Systems has helped Ghelma increase the value of its products with a bespoke solution tailored to its application.
Ghelma, a leading Swiss construction company, needed a solution to process excavation material as well as sand and gravel, much of which was previously considered waste.
To address this challenge, Terex Washing Systems, in close partnership with distributor, Avesco AG, delivered a bespoke washing solution tailored to Ghelma’s needs.
Avesco AG is the official distributor for Terex in the Swiss market. The family business has been around for more than 150 years and focuses on supplying capital construction equipment to customers across Switzerland, the Baltic States (Estonia, Latvia, and Lithuania), Finland, Austria, and Slovenia.
The companies have collaborated on various tailored solutions for customers, including for Albin Borer AG, a Swiss company focused on construction,
designed to maximise the recovery of highvalue materials and integrate state-of-the-art washing and recycling technology.
The design included an H9 Feeder, PS60 Logwasher, FM60C-2-Grade double wash sand plant, 12x5-two-deck pre-screen, 6x2 trash screen, and 8x4-three-deck full rinser post-screen, TC4026 stockpile conveyors, a fresh water pump, and a settling pond.
The PS60 Logwasher enables robust scrubbing and removal of tough clays and contaminants, which is suited to Ghelma’s natural sand application. The PS60 Logwasher was key to scrubbing the heavily contaminated material, ensuring a clean material output.
The 12x5-two-deck pre-screen efficiently pre-screens material to remove undersized material and improve yield. The 6x2 trash screen helps separate unwanted material, including organics and debris, further
of high-quality sand materials. The freshwater pump helps ensure water circulation while processing occurs, while the settling pond enhances the site’s water treatment and recycling, supporting its water management.
CONVERTING WASTE INTO VALUE
Terex Washing Systems, in collaboration with Avesco AG, is providing a solution that turns previously waste material into highvalue products. By processing excavation material and natural sand and gravel, the plant produces a range of materials for the construction material market.
Ghelma produces a variety of products, including +32mm oversize, 16/32mm aggregate, 8/16mm aggregate, 4/8mm aggregate, 1/4mm sand, 0/1mm fine sand, and trash, mainly organics.
rinse and classify materials into final products
washing, which helps Ghelma produce a range
The collaboration throughout the project ensured that Ghelma could maximise material recovery while reducing operational costs associated with waste disposal. The plant’s ability to process and refine previously considered unusable materials into highquality products is not only cost-effective but also supports Ghelma’s commitment to sustainability and the circular economy.
WORKING IN CLOSE PARTNERSHIP
Throughout the project, Terex Washing Systems worked closely with Ghelma and Avesco AG, maintaining strong communication and collaboration at every stage.
From the initial consultation to the plant’s installation and commissioning, our teams ensured that the solution was customised to fit Ghelma’s exact needs, providing ongoing support to ensure the plant’s performance exceeded expectations. This approach fostered trust and ensured the project was a success, reinforcing the value of working in close partnership with customers.
PROMOTING THE CIRCULAR ECONOMY
The advanced washing solution not only delivers high-quality materials but also
Terex Washing Systems’ new bespoke solution for Ghelma.
promotes a circular economy by recovering and recycling resources which minimises the need for virgin resources. The inclusion of water recycling systems, such as the settling pond, further supports sustainable operations by reducing water consumption.
ENVIRONMENTAL AND ECONOMIC IMPACT
The project has delivered multiple benefits to Ghelma, including waste reduction, resource efficiency, water conservation, cost savings and sustainable growth.
The new system can help Ghelma divert materials from landfills and repurpose them for construction while maximising the use of all materials processed at the site.
The system enables efficient water management through on-site water recycling through the integrated water treatment system. This has led to increased cost savings through reduced disposal costs and generating revenue from recycled products.
The sustainable focus of Terex Washing Systems’ solution has reinforced Ghelma’s sustainability commitment.
“This advanced washing plant not only enhances Ghelma’s operational efficiency but also supports their sustainability goals
by promoting the circular economy and conserving resources. This project is a testament to the benefits of working closely with customers and distributors,” Terex said.
Terex Jaques is committed to delivering quality solutions directly to customers through a streamlined direct sales approach.
This model ensures that clients have a personalised experience from initial inquiry to project completion, which can help efficiently address their specific washing needs. • For
Terex Washing Systems’ solutions are used by customers around the world.
The new solution has helped Ghelma’s business operations.
Images: Terex
BETTER TOGETHER
Bulk Handling Technologies and Total Rockbreaking Solutions’ partnership enables quarries to access better equipment solutions.
Total Rockbreaking Solutions (TRS) and Bulk Handling Technologies (BHT) share a lot. They’re located in the same headquarters in Kewdale, Western Australia, and even share a director in Paul Ingleson.
Ingleson launched BHT six months before he partnered with Jeff Jackson and Mark Godsell to create TRS. All three remain involved in the business.
The similarities are not immediately apparent, given BHT’s focus on delivering bespoke bulk-handling equipment and TRS’s focus on boom systems, boom control technologies, and a wide range of specialist hydraulic attachments. However, Ingleson saw an opportunity for the two businesses to complement each other in helping customers in Australia’s quarrying industries.
“The idea was that while TRS focused on rockbreaker products and attachments, BHT would provide engineering support if and when TRS needed it,” Ingleson said.
“There’s no competition as each company focuses on different segments of the market. We grow together, and we’ve been doing so for the last decade.”
The businesses’ two workshops cover 3,200 sqm, with additional room for lifting and handling capabilities as well as specialised capabilities.
TRS has specialised rockbreaker service pits and a boom testing area with a dedicated rockbreaker boom testing frame.
Customers can also access the training facility, where they can learn to remotely operate a training boom in a dedicated space.
“Working together under the same roof means that TRS can take on a broader scope and manage larger projects that complement its equipment,” Ingleson said.
“If a customer has a special requirement, TRS has the added engineering capacity to meet that requirement in-house.
“For BHT, it means we can complete projects end-to-end.
“We can do the design, manufacturing, assembly and test work in-house.”
TRS has long been a presence in the quarrying industry, known for its range of hydraulic attachments, boom systems, and tailored solutions, which help create safe and more efficient quarries.
The company has supplied purpose-built rockbreaker boom, boom control and hydraulic power systems for big and small quarrying operations using its expertise in the mechanical and hydraulic design of heavy-duty fixed boom systems. TRS is the authorised Western Australian dealer for Rammer, ALLU, SIMEX, PneuVibe and Daehan hydraulic attachments.
The TRS team can use its industry experience to help customers understand the right attachment for their application, whether it involves rockbreaking, crushing, or road construction.
This is where its partnership with BHT can help quarry customers, as they possess the engineering and project management capabilities to see a project through to completion.
“It means that no request is too hard. We have a vast amount of experience and talent across the two entities, which means we can respond quicker and provide innovative and custom solutions where required within very short time frames,” Ingleson said.
“The way we work is seamless. Often customers don’t realise how integrated the companies work day-to-day until we explain it to them, and straight away they see the benefits,” Ingleson said.
“We’ve had customers come to visit us at the workshop to see a boom system test with TRS, and then at the other side of the workshop is the belt feeder BHT is assembling for the same project.”
While TRS has been established in the quarrying industry for more than a decade, its focus remains the same today as when Ingleson, Godsell, and Jackson first established it. The business aims to help more Australian quarries improve safety, minimise downtime, and move more materials at a lower cost.
“We’re focused on product development and innovation. Spending extra time on a product is worth it to make something perfect. It’s important to all of us that we are making this equipment here and making it well,” Ingleson said.
“We’re starting to see real growth in enquiries and our product line, but most importantly, our long-term goals are to keep maintaining excellent customer relationships.
“Without strong relationships, there’s no business. For us, it’s all about what we can do to make a customer’s job safer and easier.” •
For more information, visit totalrockbreaking.com.au and bulkhandlingtechnologies.com.au
(L-R) Jeff Jackson, TRS director and sales manager; Mark Godsell, TRS director and service manager; Paul Ingleson, TRS and BHT director and engineering manager.
site solutions
“We capture data of your site then analyse this data to implement a customised solution tailored to your site’s requirements.”
Andy Oliveira - CJD Sales Manager - Site Solutions
ADVANTAGES
Ability to manage multiple sites and projects from one portal
Brand Agnostic
Ability to change guidelines on site for vehicles, routes & zones
A VALUABLE FLEET TOOL
Komatsu’s myFleet platform is designed as an innovative solution for fleet management within the quarry.
Managing a fleet of heavy quarry equipment can be complex, especially when information is spread across multiple platforms. That is why Komatsu has developed myFleet, a platform that simplifies quarry fleet management and centralises all machine-related data into a single, easy-to-use platform.
Steve Williams, national manager for ICT and fleet management at Komatsu Australia, oversees many of the platforms that help customers get the most out of their Komatsu equipment.
Williams and his team specialise in data analytics, using insights from customers’ machines to help optimise their operations and machine’s performance.
“We are always working on new platforms and tools to support our customers, and myFleet is one of our latest innovations,” Williams said.
“Available at no cost to all Komatsu aftermarket account customers, myFleet makes fleet management easier and more effective.”
Service technicians at Komatsu have used an internal tool since 2016 to manage on-site machine servicing.
After customers saw how efficient the internal tool was, they wanted to access their data in a similar way. This led to the release of myFleet in 2023.
“In the year since we launched myFleet, the feedback we’ve received from customers has been incredibly positive,” Williams said.
“We’ve heard how much easier it is to have all their machinery-related information in one place, and many have reported efficiency improvements, cost savings, reduced downtime, and smoother operations overall.”
The myFleet platform gives Komatsu Australia’s customers a comprehensive view of their fleet, including details about the location of the fleet, operational trends, and fuel consumption.
It also provides service reports that include defects identified during maintenance performed by Komatsu, the latest fluid sample results with recommendations, and undercarriage inspections Komatsu has completed on the machines.
“By consolidating this information into one platform, myFleet gives customers a clear understanding of their fleet’s past and future activities,” Williams said.
“You can receive alerts for upcoming routine and periodic maintenance, which helps to plan ahead and avoid any surprises.
“For example, if a loader is due for a 500-hour service, myFleet will alert users in advance.
“This gives them plenty of time to either order the necessary parts for a self-service or schedule a service appointment, directly through the platform.”
The myFleet platform is especially valuable when it comes to minimising downtime. With visibility into upcoming service schedules, based on the machine’s current usage, myFleet helps to align maintenance with project plans, keeping operations running smoothly.
“We know how frustrating it is to be in the middle of a job and realise that a machine needs servicing,” Williams said.
“With myFleet, users can plan ahead to keep their fleet and projects on track.”
IMPROVE PRODUCTIVITY AND REDUCE DOWNTIME
The myFleet platform also helps to monitor and track machine health by collecting data from platforms like Komtrax, Komatsu’s remote monitoring system that comes free with all new and used Komatsu equipment.
This data can alert customers to potential issues, such as machine abnormalities or defects identified during services, and allows them to be addressed before they lead to costly downtime.
The quarry sector is often met with productivity challenges. The myFleet platform provides valuable insights into machine’s historical data, which helps to find opportunities for improvement. For instance, Komatsu’s Payload Meter – compatible with select machines – measures the weight of each truck payload and tracks machine movements. Komatsu’s myFleet platform integrates this data into its dashboard, offering insights into idle time and operational workload, so users can boost productivity.
AN ASSET FOR SUSTAINABILITY REPORTING
As sustainability becomes more important in the construction and quarrying sector, many customers are now required to monitor carbon emissions, especially those from fuel usage. The dashboard in myFleet gives users access to detailed data on both fuel consumption and the carbon emissions produced by each machine.
“The ability to review and analyse fuel consumption within myFleet is a powerful tool in our customers efforts to reduce emissions,” Williams said.
AN INTEGRAL TOOL FOR QUARRIES
One year since the platform launched, myFleet has become a valuable tool for Komatsu machine owners. It combines telemetry and inspection data from their machines into one place. It provides significant benefits for a small, family-owned business or a large-scale quarry operation. “We are committed to continuously developing myFleet, adding new features and functions to support customers as they grow their business. Gone are the days of juggling multiple platforms to manage your fleet,” Williams said. •
For more information, visit my.komatsu.com.au/my-fleet
CDE’s tailored equipment is helping a key supplier to the Sydney construction market.
PF Formation, a third-generation family business, was established in 1956 by company founder Glen Graham. Now managed by Glen’s grandsons Joshua and Luke Graham, they sought to expand the company’s operations.
The company continues to strive to improve the business, the environmental controls, and the relationship with the local community. Luke and Joshua had a vision to improve sand quality and supply to the Sydney market where demand outstrips supply.
Luke Graham, managing director at PF Formation, said their initial impression of CDE was a positive experience.
“We first met CDE at ConExpo in 2020, and we’ve been impressed with the design and technology of CDE’s solutions from the getgo. Our main aim with this investment was to understand how we could process more material effectively and CDE had the means to support us on this journey,” he said.
“After some initial discussions, we went on some site visits in South Australia which is what really got the project over the line. We knew CDE’s solutions were second-to-none, but once we saw the technology up close, we saw just how precise and efficient it can be.
“CDE’s business development manager Jason Hartmann and the rest of the team spoke very highly about the brand, and it made us feel like they were proud to represent it, which helped us really trust in CDE’s vision for us.”
Joshua and Luke made the decision to partner with CDE and commissioned a new 400tph plant.
OPTIMAL PERFORMANCE
PF Formation’s plant is equipped with CDE’s innovative SmartTech technology which enables customers to understand their plant’s performance, schedule maintenance and easily order parts.
Sensors fitted to a plant provide up to 300 precise data points and continuously stream real-time, in-depth performance reports. Providing a full and transparent overview of
the health of a plant, this live feed is accessible 24–7 through a mobile app.
With this technology, PF Formation can watch input feed rates, the hopper speed, thickener and water tank levels remotely.
In addition, with the ability to track the volume of tonnes in versus the volume of tonnes out, PF Formation can easily identify yields for the day and analyse production data daily to anticipate how much sellable product they will have, in turn, predicting approximate revenues.
“CDE’s solution is allowing us to maximise resource yield, maximise equipment life, minimise waste and maximise return on investment, it is everything we could want in one plant,” Graham said.
“The plant really does have the wow factor, and our clients see potential for best quality fine sand for the construction industry across Sydney.
“CDE has supported us in providing the most optimal solution for us, a solution we’re proud to have invested in and that’s making a real difference to the business.”
sump, two counter flow classification unit (CFCU) density sizing and classification systems, an AquaCycle thickener primary stage water management, and an AquaStore water tank.
The L45 feed hopper, with a capacity of 44 tonnes, is one of CDE’s largest models. The feed hopper is equipped with 150mm oversize protection grid and is fitted with hydraulic tipping grid and lined hopper bin to maximise ease of material flow. The feed hopper is directly fed by a truck which contributes to the high feed rate of the plant and the efficiency of the whole operation. The feed conveyor includes scales which record feed tonnage to the plant, supporting PF Formation in monitoring inputs.
After pre-screening, the 0–3mm material is pumped to cyclones for an initial wash, removing the first percentage of the silt and then gets fed to the attrition cells, which are used to scrub the sand and liberate any fine clays and silts that are stuck to sand particles. The slurry is then pumped to another set of cyclones which will remove more clays
The CFCUs provide an effective system for removal of lightweight contamination from fine material fraction. Water is then removed from the CFCU underflows on the dewatering screens and the clean sand is then stockpiled through the radial conveyor.
CDE’s AquaCycle is a highly efficient water management solution that minimises costly water consumption by ensuring up to 90 per cent of the process water is recycled for immediate recirculation. All cyclone overflows are fed to the AquaCycle, where the solids are settled out and pumped to customer ponds. The recovered water, which is now solids free, is pumped back around the plant for re-use.
PRODUCTION OF HIGH-QUALITY PRODUCTS
CDE’s solution is allowing PF Formation to produce fine sand and a 0-3mm sand which is supplied for use in mainly concrete in the local area.
Due to the CFCU technology, which offers greater control over sand classification and
provides complete flexibility to produce various end products, PF Formation can produce a high-quality concrete sand with a specification of less than 6 per cent by volume sand and attrition cell bypass sand for brickies loam and pipe bedding.
PF Formation supplies tertiary sand to the local market. It is one of the two distinct sand types in the area and is found in the southern Maroota area. This sand type is mainly used in concrete related products in the Sydney market such as the manufacture of bricks, pavers, masonry blocks, concrete pipes, roof tiles and a large proportion of concrete plants throughout Sydney.
Hartmann said it had been a very rewarding process working with PF Formation.
“CDE and PF Formation have similar company values, forming the foundation of this fruitful relationship. We’re likeminded and passionate about the industry, and we saw from the beginning that PF Formation wanted to better serve the local community,” he said.
“We’ve been able to learn from this family run business, that for generations has been building its own wash systems.
“We’re proud to be supporting Luke, Joshua and the wider team in maximum recovery of valuable fines from sand and utilising the most from a natural resource and we look forward to developing this partnership further.” •
For more information, visit cdegroup.com
• Ideal for processing overburden, riprap/armour rock, limestone mixed with fines, clay and sticky materials
• High capacity, handling up to 500 tons per hour and up to 800mm sized rocks
• Hydraulically adjustable chassis riser for greater stockpile capacity and ease of access
• A tracked machine that’s perfect for moving from site to site
CDE has supplied a 400tph plant to PF Formation.
MORE THAN JUST PUMPS
Toolkwip Pumps provides quarries with the tools they need to handle much more than just pumps.
Water plays an important part in a quarry, but when there is too much, that is when the headaches start.
Most quarries are pits that extend below the water table, meaning water will begin to pool and interrupt the quarrying process.
The solution to this problem is pumping, and since 1993, Toolkwip pumps have provided the quarry industry with the tools needed to handle this important task.
The company has a wide range of highquality industrial pumps and equipment, with a focus on customer service.
It can provide everything from initial consultations and advice regarding the most suitable equipment for site requirements, through to installation, ongoing technical support, and the provision of service technicians for regular pump maintenance.
The family-owned and operated company is renowned for its ability to customise solutions to better meet clients’ needs.
Toolkwip’s dedicated team of industry experts boasts more than 30 years of collective
KEY PRODUCTS
Suction hoses
Suction hoses are an essential component in the management of water at a quarry. Selecting the right one is crucial to ensuring optimal performance and longevity of the pumping system. Toolkwip stocks a range of suction hoses available in different materials in standard sizes and lengths which can be cut for specific requirements.
Pumps
When water or sludge needs to be removed from site, Toolkwip provides environmentallyfriendly, efficient and reliable equipment that is essential to complete the task.
It offers a wide range of dewatering, submersible, and bypass pumps, with popular brands including:
• Selwood auto-prime pump sets
• Flo -Kwip trash pumps and submersible pumps
• Hydra-Tech hydraulic submersible pumps
• Sulzer submersible dewatering pumps
Toolkwip Pumps is the authorised distributor of the complete range of Selwood Pumps across Victoria, NSW, Queensland, SA and Tasmania, and maintains a full inventory of pumps and parts for the leading UK brand.
The Selwood range of Super Silent Pump units are ranked the quietest pumps on the market, based on the EU directive 2000/14/EC.
Selwood super silent canopies significantly reduce noise for the comfort and safety of workers and the public in projects near urban and residential areas.
They are engineered to a high technical standard, complete with silencers and protective enclosures, and incorporate sound attenuation on both diesel and electric motors.
Toolkwip Pumps also manufactures Flo-Kwip pumping solutions, built for Australia’s toughest sectors: construction, mining and quarrying.
Layflat
Toolkwip stocks a range of Layflat hoses in several different grades, each with a different pressure rating and wear life.
Lengths of 20 metres are standard or can be supplied up to 200 metres and fitted with a range of couplings, including camlocks, bauers, and flanges. They range in size from 25mm through to 900mm.
Road ramps
Flo-Kwip road ramps are designed to provide safe transfer of pumped water across roadways and footpaths, safely and with minimal disruption to traffic flow.
Designed for minimal water friction losses, they boast dedicated load-rated lifting points and hold-down/retention points.
With customisable flange sizes, they are easy and fast to install, are transportable and stackable, and are available with 4in, 6in or 8in connections.
Toolkwip Pumps provides solutions for Australia’s toughest sectors.
Toolkwip promotes the routine maintenance of pumps to prevent breakdowns
Standpipes
Custom-designed and engineered to meet the harsh demands of the Australian environment, the high-quality standpipes are designed for reliability and efficiency in water transfer and are an essential piece of equipment for water supply.
Available with engineer certification, these standpipes are available in 4”, 6” and 8” pipe sizes and are in a range of heights to suit different water carts.
The standpipes are also collapsible for ease of relocation and transport and available with forklift lifting channels.
The range has painted/hot dip galvanised or poly options and comes standard with layflat hose on discharge.
On-site audits, service and repairs
Toolkwip Pumps prides itself on after-sales service, providing on-site and in-workshop repairs, and service for customers.
Toolkwip’s services extend beyond supply. The company can also provide
comprehensive services for pump repair, servicing, and rebuilding.
Pump downtime is not merely a temporary pause in operations – it’s a disruption that resonates throughout a project, leading to missed deadlines, distracted staff, unhappy customers, and potentially severe financial implications. It can also sometimes cause flooding issues on the site, leading to costly and time-consuming clean-up operations.
With in-depth industry knowledge and extensive experience, Toolkwip offers services to efficiently counter these downtime challenges. The company is committed to helping customers maintain uninterrupted operations by providing rapid and reliable services that keep the pumps working at their optimal capacity.
Toolkwip is not just about fixing pumps; it’s about providing comprehensive solutions that cover every aspect of pump operation. These services include design and fabrication of pump-related equipment, troubleshooting of pump systems and pipework, noise and
vibration analysis, servicing and rebuilding of diesel engines, and providing electrical services. By offering a wide range of services, Toolkwip positions itself as a one-stop-shop for all pump-related needs. This holistic approach streamlines operations, cuts down on administrative hassles, and ultimately, saves time and money for the customer.
Toolkwip takes a proactive approach to equipment management, promoting routine maintenance of pumps to prevent breakdowns and ensure reliable and efficient operations. By identifying potential issues before they escalate into major problems, Toolkwip helps to reduce downtime and associated costs. •
For more information, visit toolkwippumps.com.au
Toolkwip’s team boasts more than 30 years of collective industry knowledge.
CUSTOMISED SOLUTIONS FOR MAXIMUM EFFICIENCY
Why one-size-fits-all approaches can fail in wet sand processing and how tailored approaches drive performance, profitability and sustainability
Achieving optimal sand production and fines recovery requires solutions tailored to each operation’s specific parameters. A one-size-fits-all approach often fails because wet processing conditions vary highly across different sites.
To optimise wet processing, it’s essential to choose equipment that matches the application’s specific requirements. Whether you are integrating a new wash plant or improving an existing circuit, finding the correct equipment configuration is critical.
Brett Casanova, washing product manager at Superior Industries, said that to achieve optimal performance, a thorough analysis of plant operations, material properties, and capacity needs is necessary. With the right data and access to a broad range of washing components, Superior’s engineers develop customised solutions designed for maximum efficiency and cost-effectiveness.
Key considerations:
• How can efficiency be maximised in wet processing?
• What technologies can reduce or eliminate pond maintenance?
• Which equipment configurations will best produce clean sand while recovering fines? Implementing targeted, customised solutions that address specific operational needs can answer these questions.
Casanova spoke to Quarry about the benefits of approaching wet processing this way.
COMPREHENSIVE EQUIPMENT TOOLBOX
Solving wet processing challenges requires a wide variety of equipment. Every application has unique requirements, such as material type, moisture content, water availability, and footprint constraints. A broad selection of washing components is necessary to meet the needs of multiple stages, from scrubbing and classifying to washing and dewatering. Superior offers a complete line of customisable washing components and systems that can be tailored for specific applications.
This flexibility allows producers to maximise cost-efficiency by selecting the appropriate equipment for each stage of wet processing.
Superior’s ability to provide a comprehensive suite of equipment is a distinct advantage, allowing for seamless integration across plant systems without relying on external vendors for key components.
Effective washing removes unwanted particles such as lignite, mica, and silts while ensuring products meet specifications.
Below is an overview of critical sand washing technologies used in various applications.
FINE MATERIAL WASHERS
Fine material washers are widely used for removing silts and dewatering material. These systems are easy to maintain and reliable, capable of handling silt cut points ranging from #200 to #100 mesh. Often, they are used after classifying tanks for further dewatering.
However, given the increasing presence of dirtier pits, more advanced solutions may be necessary to address challenging material conditions.
CLASSIFYING TANKS
Classifying tanks are ideal for separating fine materials based on size while removing silts. These tanks use water and gravity to separate material, which is then blended to meet specific requirements. Precision control through automated valve systems ensures accurate material specifications.
Classifying tanks are frequently used in dredging operations, where they help remove excess water from sand.
SPIRIT SAND PLANT
The Spirit sand plant is a modular system that provides efficient sand production, fines recovery, and dewatering. It combines components such as Superior’s helix cyclones, dewatering screens, sump tanks, and slurry pumps. Each plant is configured to the specific application, ensuring the appropriate cyclone and screen combination for the desired cut points.
Cyclones are especially useful in areas with limited water resources or where space for settling ponds is restricted. Cyclones can efficiently remove silts while improving fines recovery.
ALLIANCE LOW WATER WASHER
Many crushing operations face challenges with water usage. The Alliance low water washer addresses this issue by using significantly less water while washing crusher dust directly next to the crushing circuit. This system reduces the need to transport material to separate washing systems, lowering operational costs and improving efficiency.
AGGREDRY WASHER
The Aggredry dewatering washer is an energy-efficient alternative for wet processing applications, providing precise sand specifications with low moisture content. The system uses minimal horsepower and significantly reduces drying times by producing a final product with a moisture content as low as 8 per cent.
The Aggredry also recycles water within the system, making it an ideal solution for operations with limited water availability.
PRODUCING CLEANER SAND
As easily accessible sand reserves become depleted, producers are forced to process dirtier deposits. The right combination of washing technologies can help optimise efficiency across multiple stages of wet processing. For example, adding a fine material washer after a classifier can improve dewatering, while installing a cyclone ahead of a classifying tank can handle material with high fines content.
Superior’s modular Spirit sand plant provides flexibility by allowing producers
to configure washing systems based on specific site conditions. This adaptability ensures that sand washing systems are capable of handling increasingly challenging applications.
TOTAL PLANT EFFICIENCY
Achieving total plant efficiency requires careful management of all components in the processing chain.
A poorly maintained piece of equipment, such as a faulty sand screw, can result in valuable material being lost to the settling pond. It’s critical that all equipment is functioning optimally to ensure material is properly processed and recovered.
Selecting the right wet processing solutions is only part of the equation. Expert support is essential throughout the entire process, from initial design to installation and ongoing maintenance.
Superior provides both innovative equipment and the necessary expertise to ensure reliable and efficient plant operation.
Optimising wet processing requires more than standard equipment choices. It demands a thorough analysis of site-specific conditions, the use of tailored washing solutions, and the support of experienced engineers to ensure the right fit for every application.
Superior Industries’ application specialists collaborate closely with producers to finetune total plant performance.
Whether the customer is adding a new wash plant or tweaking an existing circuit, it’s vital to find the right fit.
“It all depends on a thorough, expert analysis of your application, overall plant operations, and capacity requirements – and properly addressing each unique parameter and product specification,” Casanova said.
He said that when armed with the correct data – and a “complete toolbox” of washing components, systems, and equipment combinations – Superior’s expert sand processing engineers “dial in” desired specifications with customised solutions that deliver maximum efficiency at the lowest costs per tonne.
The right solutions require a complete toolbox. Not just one or two commonly-used equipment options.
Application parameters are numerous – from material type, moisture content, specification requirements, footprint size, permitting restrictions, financial limitations, water rates, water availability, and more. Plus, equipment solutions are required for multiple stages of wet processing from scrubbing, to classifying, washing, and dewatering. Obviously, the latter is best supported by a toolbox that includes a complete array of customisable washing components, plants, and equipment configurations – combined with the expertise of washing application engineers.
Whether manufacturing sand or washing the dirt out of an already in-spec product, accessing a complete toolbox ensures not only the right solution, but also the most cost-efficient one. Consider that certain more affordable solutions can be substituted for a higher capital equipment investment in various applications.
Casanova said that since Superior provides the “complete toolbox,” the company can “package” plant solutions far more effectively than those manufacturers who must rely upon outsourcing key plant components.
“Certainly, the washing side of the aggregate market is one of the biggest growth areas. Demand is across the board –not only for new wash plants, but for all washrelated products. Also, producers are looking for wash plants that require less water and a minimal footprint. They want solutions that reduce waste and maintenance, while recovering fines and gaining more saleable products,” Casanova said.
“Today’s producers require a complete toolbox, combined with the right expertise, throughout the plant’s lifecycle.” •
For more information, visit superior-ind.com
HALLETT GROUP DISCOVERS VOLVO SITE SOLUTIONS
A strategic partnership with Warrin Mining, CJD Equipment and Volvo CE Site Solutions has enhanced efficiency and productivity, and significantly improved safety at one of SA’s premier hard rock quarries.
SSince acquiring the Turo site in 2018, Hallett Group believed it would quickly become a leading operation.
“This is, without doubt, one of the best hard rock and hardest rock quarries in South Australia,” Mark Pickard, managing director of Hallett Group, said.
However, the quarry’s remote location presented unique challenges that called for a more intelligent approach to site management.
Hallett adopted Volvo Site Solutions to streamline operations. This decision allowed the company to tackle the complexities of quarry management by capturing and analysing operational data to develop customised solutions tailored to the specific needs of the Turo site.
Central to Volvo Site Solutions is the Connected Map platform — a data-driven solution tool offering real-time visualisation of all site activities and is brand agnostic. This technology gives site managers a comprehensive overview of vehicles, equipment, and personnel, enabling remote monitoring and quick adjustments to site
guidelines. The platform also facilitates the coordination of projects across multiple locations through a single interface, ensuring smooth communication and maximising resource utilisation.
STRATEGIC CHOICE
The partnership with Volvo was a natural progression for Hallett Group, underpinned by a longstanding relationship with Warrin Mining and CJD Equipment spanning over two decades. Volvo’s reputation for durability and performance was established at the site, and a Volvo 460B excavator purchased at the outset is still in operation today. Beyond the reliability of its machinery, the opportunity to incorporate Volvo’s advanced excavators, front-end loaders, and digital solutions was a key factor in the decision.
The implementation of Connected Map technology has proved transformative for Turo quarry. Managers now have the tools to monitor activities in real-time, adjust routes, and establish safety zones remotely. This comprehensive approach to site management has led to increased
Managers can monitor activities in real-time, adjust routes, and establish safety zones remotely.
productivity, lower operational costs, and a safer working environment.
OPTIMISING OPERATIONS
Volvo’s data-driven approach to productivity services provides Hallett Group with a robust toolset for optimising operations. The system continuously captures data on material movement, machine usage, and site activity, enabling detailed analysis to inform decision-making. This information is displayed through performance indicators on a visual dashboard, allowing both on-site managers and remote supervisors to track progress towards production targets and make informed adjustments.
“One of the main reasons why we chose Volvo for this semi-remote site was their connected map technology,” Pickard said.
Furthermore, Volvo Co-Pilot technology equips each machine at the quarry with the capability to set goals, monitor progress, and collaborate more effectively with the team. The site solutions are brand-agnostic, meaning they can be used across different types of machinery, regardless of the manufacturer. This integration ensures operators work towards shared objectives, fostering a culture of accountability and continuous improvement throughout their fleet.
Central to Volvo Site Solutions is the Connected Map platform.
PUTTING SAFETY FIRST
Safety is paramount in quarry operations, and Volvo’s commitment is evident in several innovative features. The Connected Map technology allows for the creation of restricted zones anywhere on-site, providing real-time alerts for approaching traffic and managing one-way road access. Additionally, a visitor app enhances site security by ensuring that all personnel and visitors are always accounted for. These measures reduce the risk of accidents and contribute to a more structured and controlled site environment.
“More specifically, it was the individual monitoring of each item of plant and the operator and the performance of that operator on those items of plant,” Pickard said.
“It has allowed us to be able to, in realtime, understand where that equipment is on-site, what its performance and operating efficiencies have been - better than any
other manufacturer that’s out there in the marketplace.”
COMMITTED TO A SUSTAINABLE FUTURE
In the future, the partnership between Hallett Group, Volvo CE, Warrin Mining and CJD Equipment is committed to promoting sustainable growth in the quarrying industry. The collaboration focuses on reducing carbon emissions and improving operational efficiency, setting an example for using innovative technology to achieve sustainability goals. The continuous development of datadriven solutions shows the potential for more intelligent, environmentally friendly operations in the sector.
By adopting Volvo Site Solutions’ advanced tools like Connected Map Co-Pilot and Performance Indicator, Hallett Group has overcome the challenges of its remote location while significantly enhancing productivity, efficiency, and safety. The
enduring partnership with CJD Equipment and Volvo has provided dependable machinery and practical solutions and fostered a culture of continuous improvement and sustainability.
“One thing that Volvo has done is listen and understand what we need as a quarry operator in managing our plant and fleet onsite”. Pickard said.
“The backup support from Warrin and through CJD has allowed us to implement that system as efficiently and productively as possible on this site and its evolution.
“What we do today will hopefully be very different from what we do tomorrow, and that’s the confidence I have in Volvo in being able to listen to us and then implement these micro changes that we need to make on this site and others to be as efficient and as productive as possible.” •
For more information, visit cjd.com.au
Securing a sustainable supply of concrete sand for construction
When mobility and toughness matter, count on the Lippmann 300c and 400c. These mobile cone crusher plants were specifically designed to take on the most abrasive and toughest materials in aggregates and mining — all with mobile capabilities. Heavy duty cone crushers with an innovative material flow that maximizes capacity and throughput while delivering a consistently high quality product.
The MDS M515 Heavy Duty Trommel excels at crafting rip rap and reclaiming rocks entangled with clay and other adhesive materials. Comes complete with fold out stockpiling conveyors and has four hydraulic jacking legs to raise the machine to increase stockpile capacities and lower for transportation. See triconequipment.com.au or call 1300 859 885
Superior’s Telestacker® Conveyor is a material handler’s most effective weapon against costly stockpile segregation. Its variable height, length, and axle positions allow for layered stockpile construction, which is key to achieving partially and fully desegregated piles. The design has been carefully fine-tuned for hard work and dependability in numerous applications. Call Tricon on 1300 859 885 or see triconequipment.com.au
SUITABLE SELECTIONS
Precisionscreen’s sand-washing range is made for Australian conditions.
Demand for natural or manufactured sand is rising in the Australian market, so having the right equipment is essential.
Precisionscreen has developed its sandwashing equipment range over several years to ensure it could help the smallest of sand producers to the larger players in the sector.
Jonny McMurtry, chief operating officer at Precisionscreen, told Quarry he believed there would likely be continual strong demand for the material.
“There has been an increase in demand for sand washing equipment as I think there is increased demand for washed sand in the market,” he said.
“As the volume of infrastructure continues to be there and climb the requirement for sand isn’t going to go away.”
The market for washed sand and manufactured sand is becoming more diverse as quarries explore how they can use the material to either expand their offering to the market or add new revenue streams.
Original equipment manufacturers like Brisbane-based Precisionscreen have developed a wide range of sand-washing equipment to suit specific applications and help customers take advantage of the growing demand. In one case, Precisionscreen worked with Victorian-based
construction materials supplier site to create a sand-washing solution for their manufactured sand application. The company has employed the use of a sand screw from Precisionscreen to create a manufactured sand using washed crusher dust.
“Our sand washing equipment has been developed over a number of years and we offer different machines for different applications or customer price ranges or throughputs,” McMurtry said.
Precisionscreen has built out its range of sand washing equipment to provide solutions for customers from the first stage of washing to the final stage. The company manufactures all its sand washing equipment at its headquarters in Wacol, Brisbane which gives it the distinction of being Australian made.
The company’s adaptable wash kits have a range of customisable features to tailor the kit to the customer’s specific application. The Precisionscreen wash kit can range from single deck to two or three-deck kits which are built on the screen box.
Each deck has multiple spray bars with several spray nozzles to rinse the product being processed.
Operators can finely control the individual gate valves to each bar which provides enhanced control and excellent washing coverage.
“The wash kits as part of our screen boxes are probably the first step for sand washing,” McMurtry said.
“We sold quite a few of those this year, predominantly for sand washing but even washing pebbles or rinsing different products to remove dust has been in demand.”
Precisionscreen Sandscrew has also been in demand from customers across Australia due to its versatility. It can work alongside Precisionscreen’s wash kits or other wash plants to help dewater and classify sand products.
The sand screw has a hydraulic drive and features a mobile-wheeled axle as well as an adjustable overflow weir. The Sandscrew can be operated off the Precisionscreen’s screening plant powerpack.
The spiral screw helps separate heavier particles as they sink to the bottom of the trough after being dragged through the trough by the spiral screw. Dewatering occurs throughout the trough until the finished product is discharged via a chute.
“Our Sandscrews have been quite a hit just due to the adaptability. It can work with existing screening plants or existing applications if needs be. We’re one of the few manufacturers that makes our sand screws semi-mobile so it can couple up with existing systems if needed,” McMurtry said.
Precisionscreen has a wide range of sand washing solutions for customers.
“The sand screw is probably on the lower end with throughput and cleanliness of sand but it has performed very well [in creating] a manufactured sand where it is quite suitable and economical for that type of application.”
Precisionscreen has also created a modular sand washing plant which combines a galvanised 10x5 two-deck wash screen with a SRD180 bucket wheel dewaterer and a fines recovery pod to create a one-stop solution for sand producers.
It allows operators to create up to three different sand fractions and accept material from a dry screening process via conveyor
belt or cyclone mounted above the screen.
The SRD180 bucket wheel dewaterer collects sand particles from slurry materials in a wet screening process with its primary responsibility being to pick up heavier particles of sand as they sink to the bottom of the tank. It can manufacture coarse and fine grade sands simultaneously. It features a submerged back screw which helps float off unwanted silts while its large water overflow area and polyurethane bucket inserts provide a sizeable dewatering capacity.
The FRP has a 250mm cyclone on-board, discharging heavy particle sand onto the high-
frequency dewatering screen for draining. The screen helps remove unwanted materials, excess water or organic materials from the sand material. The cyclone and screen are hydraulically driven and designed to work with Precisionscreen’s washing plants.
McMurtry said the SRD and FRP had benefits even as standalone products for Australian operators.
“The SRD180 or the FRP gives a greater throughput and a cleanliness of the sand as well and that’s where it comes into its own.
“If you have a high silt content and you need to float off a lot of that bottom end product in that super fine sand, that’s when the likes of the SRD or FRP comes into its own,” he said.
“If a customer has water restrictions or low access to water that is where the FRP can allow any residual water to be taken off your sand product quite quickly and easily. Or it can use the cyclone to take out the super fine sand to recycle that water quickly.” •
For more information, visit precisionscreen.com.au
GET PUMPED WITH
Precisionscreen designs and manufactures its sand washing equipment in Brisbane.
XMOR BUCKET LASTS THE DISTANCE
Quarry owner Rob Matthews details his company’s experience using the XMOR Bucket from ONTRAC Group.
When Matthews Quarries wanted to increase its production, the excavator bucket was at the forefront of its strategy.
Since its establishment in 1986, Matthews Quarries has grown to delivers more than 500,000 tonnes of material annually to the Gippsland region and beyond.
Focusing on providing high-quality quarry products and technical advice, Matthews Quarries pairs its operators with leading equipment to do the job. Recently, the company invested in the XMOR Bucket from ONTRAC Group to partner with its Volvo 750 excavator.
“It’s saving us money. The XMOR Bucket fitted to our Volvo 750 Excavator is doing at least 10 per cent more than what our previous 75-tonne Volvo was doing with a standard bucket, so it’s proving itself,” said Rob Matthews, owner of Mattews Quarries.
“We’re only doing overburden of clay and dirt at the quarry, so it’s lasting very well. There’s no maintenance to do to it.
“It loads a lot quicker. We were previously doing five buckets to get a load, and now we’re doing three. It’s four if they don’t get a full bucket; it just depends on what they’re
doing and where they are at the time. But it doesn’t unbalance the machine either.”
ONTRAC Group is the exclusive distributor and manufacturer of the XMOR Bucket in Australia. It features a unique, curved design with patented keel and heel segments to reduce the required passes.
The XMOR Bucket is manufactured from with SSAB’s Hardox 500 Tuf wear plate and Strenx 700 structural steel, making it lighter than conventional excavator buckets available. Due to the steel’s durability and the XMOR Bucket’s curved design, it does not sacrifice service life.
The inverted shape of the tub minimises ground contact and wear of the bucket’s bottom, reducing customers’ maintenance and servicing requirements.
Matthews said the XMOR Bucket had helped the Gippsland-based business boost its productivity.
“The dump trucks are doing more work. Previously, they were sitting, waiting to get loaded, and now there’s very little time they’re sitting, so it’s saving fuel and labour,” he said.
“Saving fuel versus the production rate makes it quicker and cheaper. If it’s still going as strong as it is now in another 12 months’ time, it’ll be leaps and bounds ahead.
“When we buy another excavator, we’ll definitely be looking at XMOR again.”
Nick Espie, product specialist at ONTRAC Group, said the company was seeing greater uptake of the XMOR Bucket in the industry.
“We’re trying to encourage people have a new way of thinking. When the customers see the numbers and what they can achieve, especially now that we’ve got real time data, that answers a lot of questions,” he said.
“We are getting a lot of positive feedback from customers who may have been sceptical but now wouldn’t go any other way but XMOR.”
The XMOR Bucket comes in the popular BHB option, which features a lightweight, rounded design suited to bulk earthmoving or overburden work. The BHC variant of the XMOR Bucket is beefed up to deliver a more robust option for abrasive environments. It maintains the same benefits and design as the BHB model but features increased steel thickness and a flat cutting edge with a straight top beam.
ONTRAC Group’s team can conduct on-site studies to help quarries determine the best option for their application. Using a datainformed approach, ONTRAC Group can show in real time what production levels and return on investment the quarry could achieve.
“Creating a win-win situation for us and the quarry is our ultimate goal; it’s the driving force behind what we do,” Espie said.
“We believe the XMOR bucket can help quarries, and we want to work with the quarries and the OEMs to help them see how the XMOR could make them stand out.” •
For more information, visit ontracgroup.com.au
Matthews Quarries uses an XMOR Bucket from ONTRAC Group.
Image: ONTRAC Group
EDUCATION
Member access to IQA
Education Hub & Learning Management System (LMS)
Discounted fees for ALL courses
Over 100 courses, workshops, tours and events offered annually
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Professional connections
INDUSTRY RECOGNITION
Use of IQA digital member badge
Recognition membership status through post-nominals
IQA Award Nominations
Acknowledgement of industry contributions
2 IQA MEMBER BENEFITS
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Incentives for Young Members
Contribute to the industry Opportunity to join branch committees
Engagement with quarrying professionals nationally & globally
Initiatives and support for Women in Quarrying
A range of site tours and workshops, events & conferences
PROFESSIONAL DEVELOPMENT NETWORKING
MINI MACHINE MAKES WAVES
How do you turn a 25-tonne screener into a desk ornament? Quarry spoke with Powerscreen to find out.
Powerscreen is no stranger to engineering new versions of its machinery. In fact, the company’s flagship screener, the Chieftain 1700X, is based on several iterations from its 1700 series.
However, the company found it much more complicated than expected to make a version that is 50 times smaller than the real life version.
Dermot McCracken, marketing manager at Powerscreen, told Quarry that a lot of work has gone into designing and producing a scale model of the Chieftain 1700X.
“This is a new initiative for us, but it’s something that has been spoken about for a long time – it’s 20 to 30 years in the making,” he said.
“Dealers and customers have been asking for them for some time. They’re quite an investment to make, with significant startup
screening equipment though, there aren’t many that offer scale models, especially in the 1:50 scale.”
Powerscreen has previously made some models on a one-off basis for long-term dealers or retiring staff, but nothing that needed mass production.
The company took inspiration from how other industries have constructed similar models, such as crawler cranes. It needed a model that was robust, true to life, and required minimal assembly.
McCracken said several unique features emerged from this research and development process.
“We wanted to make the machines as close to the real thing as possible, and one of the benefits of the Chieftain is it can be rapidly set up from ‘transport mode’ to ‘working mode’ in as little as 10 minutes,” he said.
The Chieftan 1700X is available with a
valve change, effectively turning the machine into a two-deck screen, allowing maximum versatility with a single plant.
The conveyors on the scale model are mounted onto the chassis and fold out in a similar way to the real thing and can fold in and out of transport mode.
“We put in some minor tweaks to strengthen the conveyors to make it more robust,” McCracken said.
“These models are not toys – but we’ve designed them so that if they’re knocked off a desk or a child gets a hold of it, it won’t be easily broken.”
The Chieftan 1700X also features an adjustable tipping grid, which has also been included on the model as a moveable feature. One of the highlights is that it comes fully assembled except for two jacking legs for stability, which are pinned at the back of the machine.
“Even across other industries, our equipment is famous. A lot goes into the logistics of sending our screens from Ireland to Australia,” he said.
“We have had a lot of demand from trucking companies for the model and have heard about people who would love to connect the Chieftain to a scale model of their truck.”
In Australia, the models are available from Powerscreen’s exclusive Australian dealer, Lincom Group.
Established in 1995, Lincom Group has supplied Powerscreen equipment to Australia for almost 30 years.
As part of the strategic partnership between the two companies, Lincom provides feedback to Powerscreen to help engineer equipment for the local market.
McCracken said Lincom Group placed a significant pre-order of the scale models and is one of the first dealers globally to receive them.
“The feedback from Australia has been fantastic from customers,” he said. “One thing we weren’t expecting was the demand from collectors.”
“When we started thinking about the models, we didn’t have collectors in mind –we had thought it would appeal to customers, dealers and some of our staff. We’ve been blown away by the ongoing demand.”
The demand has been so great that
Demand for the models has exceeded expectations.
It has also sparked interest in a potential follow up-model – potentially a crusher.
McCracken also thanked Lincom for being part of this process.
“They’ve been a fantastic dealer and have been phenomenal to work with from day one,” he said.
“They regularly fly over, and we love to have the Aussies over.
Lincom has done a great job supporting the industry, and its service is second to none.” •
WHY INNOVATION IS IMPORTANT
Eltirus founder Steve Franklin explains why the quarry industry needs to foster and encourage innovation.
WWhile we take it for granted now, the wheel, the printing press, steam engine, internal combustion engine, electricity, air travel and computers have all changed our lives in profound ways. Each of these technologies took someone (or a group) to think differently, try different things, fail plenty of times in the process, but ultimately come up with a new or better idea and then sell others on it.
IMPROVING THE BOTTOM LINE
Increasing business viability is critical. It is unfortunate that at this time, making a profit seems to be equated with misadventure, price gouging and other “reprehensible” activities on behalf of business leaders, often called to question in Senate hearings and the like.
help provide the standard of living we aspire to, to enable us to care for the less fortunate in our community and be able to afford the transition to a decarbonised society.
So, what does this look like in practice?
To increase the viability of any organisation, there are only a few ways to achieve it. One way is to increase selling prices. This results in market inflation and is workable to the degree that others also increase their prices. In a commodity type market, prices can only be moved so far before restricting sales. The second way to be more productive, by increasing the utilisation of resources or by innovating and doing things more efficiently. Ultimately, there is only so far that you can go with pushing people and equipment to produce, after all there are only so many hours in the day.
Examples of innovation of the past include the move from 35t dump trucks to 60t units, resulting in one operator doing the work of two. This innovation required a considerable rethink of quarry design, fixed plant configuration and loading tool matching and took some time to become common.
At the same time, manufacturers came up with innovative technologies to reduce fuel consumption. The first 60t haul trucks (1996) burned around 50l/hr, while the current generation trucks use around 32l/hr. This change occurred through improvement in diesel engine technology that increased their efficiency.
PRODUCTIVITY IMPROVEMENT
We don’t generally hear much discussion about productivity improvement in Australia, probably with the exception of from the Reserve Bank of Australia (RBA). Philip Lowe, the former governor, often emphasised the importance of productivity improvement for Australia’s economic growth, specifically: 1. Investment in infrastructure: investing in infrastructure can significantly boost productivity by improving connectivity and efficiency.
There is a huge ecosystem of innovators in mining.
The industry’s best option to improve overall productivity is to innovate.
2. Innovation and risk-taking: The need for a culture that promotes innovation and is willing to take risks. This is crucial for driving productivity growth and adapting to demographic changes.
3. Education and skills development: Enhancing the education system and ensuring that the workforce has the necessary skills to productivity.
Lowe’s insights suggest that a multifaceted approach, involving infrastructure, innovation, and education, is essential for sustained productivity growth.
If you are interested in this subject, it is worth taking a read of the RBA report from September 2023, Recent Trends in Australian Productivity.
“Like other advanced economies, Australia’s trend productivity growth has slowed in recent decades. From the 1990s to mid-2000s, productivity growth averaged 2.1 per cent, with the economy benefiting from deregulation and pro-competition
policy reforms, the rapid uptake of new digital technologies and strong global productivity growth throughout this period. This led to a sustained period of strong income growth. Since then, average productivity growth has fallen, averaging just 1.2 per cent over the 2010s. This decline has occurred across the market sector, rather than being driven by a particular industry,” the report said.
Unless we can do something about labour productivity (difficult given the current political environment), our only real option to improve overall productivity is to innovate.
INNOVATION
The theme of both the New Zealand and Australian Quarry Conferences in 2024 was innovation and it is becoming a more topical subject generally.
You might be aware that in March 2023, the Australian Productivity Commission released the Advancing Prosperity report, emphasising the critical role of innovation in
driving productivity and economic growth.
It’s a big report and I don’t suggest you read it all. They suggested the following focus areas to consider:
1. Diffusion of innovation: The importance of spreading innovative practices and technologies across all sectors of the economy, not just within leading firms. This approach, termed “Innovation for the 98 per cent,” aims to ensure that smaller businesses and public services also benefit from new ideas and technologies.
2. Digital technology and data: The identification that digital technology and data are major drivers of productivity and that enhancing the secure use of data and digital tools can lead to significant economic gains, improve service delivery, and support regional and remote communities.
3. Collaboration and networks: Collaboration between businesses, research institutions, and government
• Equipped with two rotors to achieve a high capacity with a minimal machine width
bodies is seen as vital for fostering innovation and that it is vital that we create networks that facilitate the sharing of knowledge and resources.
4. Policy and regulatory environment: Putting in place a conducive policy and regulatory environment that supports innovation. This includes reducing barriers to competition, improving the business environment for private investment, and ensuring efficient public investment.
5. Workforce adaptability: Building an adaptable workforce through education, migration, and occupational licensing reforms to support innovation and productivity growth.
APPLICATION
So, what does it mean in practice? Each year, the International Mining and Resources Conference is held in Sydney. This year they are expecting 9000 delegates and some 500 exhibitors. In short, it brings the best and brightest in what is arguably the best mining technology country together to talk technology and innovation. The breadth of technology is
breathtaking and if you haven’t been to this show before, it is well worth going.
At the 2022 conference, the Group Procurement Manager for BHP, noted how vibrant and valuable these suppliers and innovators in Australia were and how important he thought it was for BHP to support and foster innovation through this ecosystem.
This is pretty novel thinking in Australia unfortunately.
If we go back to the Advancing Prosperity report, there are two interesting graphs – the first showing how much innovation that is being put into use is new to Australia, but not the rest of the world. It is a measly 3.3 per cent for processes and 7.4 per cent for products.
And where do the innovation ideas come from? In most cases, it is the company itself – there isn’t that much looking outside and negligible support for R&D enterprises. I think that it is very easy for companies who focus nearly entirely innovating internally to get caught in an echo chamber where they stop looking externally and focus on “proving” what they are doing is as good as it gets.
Despite the huge ecosystem of innovators in mining, the same cannot be said for the construction materials industry in Australia which would be lucky to have more than a dozen truly innovative companies working on smart stuff.
Innovation is important. In fact, it’s very important. We have to innovate and do things differently if we want to drive down costs and increase output. The technologies and ideas are often already known, but there has to be a willingness to look outside of your organisation, to try new things, knowing that they may not work out and be relentless is working to innovate and improve.
But can I also make this ask – please take the time to listen to, support and work with the innovators outside of your business – they are there out of a passion to change things and improve the businesses that they work with.
At the end of the day, I think we all have similar goals – a safer, more inclusive, productive and environmentally friendly industry that people want to be a part of and feel valued for doing so. •
For more information, visit eltirus.com
Changes in engine technology have increased their efficiency.
EUROPEAN SOLUTION TO SAND SHORTAGE
Environmental restrictions are tightening on sand mining around the world, but Magotteaux’s vertical shaft impact is providing an alternative.
While at first, sand might sound like a plentiful resource – that couldn’t be more wrong.
Some sands are better than others, with attributes that makes them more useful for things like concrete and beach nourishment.
In the European Union (EU), mining for sand is subject to numerous environmental regulations and impact assessments.
However, according to the EU’s DirectorateGeneral for Environment, sand is so valuable that “sand mafias” have sprung up to protect illegal sand mining.
While Australia’s industry has not gotten to this stage, some companies are beginning looking for alternatives.
Patrick Croix, business development manager at Magotteaux said it is becoming harder around the world to get approval for sand mining.
“The sourcing of materials in the future will move from natural resources to the cities,” Croix said.
“This is the future, we believe in Europe that from 2050, the material sourcing for highways and buildings will become more from old buildings and roads.
“And there will be a trend in countries who are looking into the circular economy to look to preserve the environment and use what is there.”
While Magotteaux has mainly made its name in Europe, working with major brands across the continent, the brand’s vertical shaft impactor, the Mag’Impact can easily have applications for the Australian market.
It has grown into a company that today has more than 3000 employees, 28 sales offices and an annual turnover of $1 billion globally since it began in 1918.
The company, which started in Belgium as a foundry, is recognised in the industry for its differentiated solutions across wear with patented ceramic technology.
The Mag’Impact traditionally comes in three sizes – 2700, 2400, 2100 with the 2100 available in a specific manufactured sand
model – and all the units can crush and shape in a single pass and be retrofitted onto installations. With this ability it can replace a tertiary cone and quaternary VSI with just one tertiary Mag’Impact. This has reduced up-front costs as well as the associated costs
The ability to provide a specific focus on sand is important given the high-level of shaping which is required to get the acceptable grade of this material.
Given the future trends towards sustainable extracting and manufactured aggregates, the
The Mag’Impact is a versatile crusher with high capability and European quality.
Images: Magotteaux
“What we’re finding is customers are appreciating the stable output sieve for sand and at the correct specification”.
Magotteaux’s team is trained to provide expert advice, services and resources, products, equipment, and systems to find the
best solution to optimise a site’s applications. Australian companies have benefitted from this optimised technology. Magotteaux account manager Darren Bowley said one company managed to double the life of its hammers.
Most of the units working throughout Europe in the past 20 years or so are in fixed plant applications. These can be mounted onto tracks or semi-mobile platforms.
Bowley said the Mag’Impact is a versatile crusher with high capability and European quality.
“It is a highly flexible crusher that could be changed out to suit other configurations if required.”
In addition to sand production the Mag’Impact can be used for Crushing hard and abrasive rocks, such as gravel, limestone and blast furnace slag for roads, concrete, and more
For more information, visit magotteaux.com
Most of the units working throughout Europe in the past 20 years or so are in fixed plant applications.
STAND-OUT SAND
Quarries across Australia have the chance to make a significant contribution to the sand industry by engineering a sustainable material from by-product.
Concrete has been an industry standard construction material for 200 years. It’s versatile and readily available. It also makes up around eight per cent of total global emissions, according to independent think tank Beyond Zero Emissions.
In addition, a key component of concrete is becoming harder to acquire – sand. The United Nations Environmental Programme estimates that sand extraction is rising at a rate it called “unsustainable”. It outlined the scale of the problem and the lack of governance, calling for sand to be recognised as a strategic resource, and for its extraction and use to be re-thought.
One of the companies helping solve this problem is Kayasand. The company was inspired by technology used in Japan to engineer sand for its construction industry following a ban on dredging in that country.
The technology has started to make waves in Australia and New Zealand, as engineered sand is put through its paces.
James Mackechnie, a concrete industry expert at the University of Canterbury in Christchurch, New Zealand has worked with concrete for most of his life.
He told Quarry about his laboratory testing of engineered sand.
“We have performed multiple trials in a laboratory setting. Replacing standard manufactured and natural sand with Kayasand’s engineered sand to see if there is potential for ready-mix producers,” he said.
“The results demonstrated a benefit in terms of cement efficiency. Less cement is needed to get the same strength in concrete with the Kayasand product.
“That’s a cost advantage and an environmental advantage – which is important because there’s immense pressure to be as economical as possible with cement in concrete.”
Kayasand’s plants can precisely control the shape and size of the sand particles, the levels of contaminants and consistency of the final product. Mackechnie said there were three main reasons the Kayasand product led to stronger concrete.
“Firstly, we need less water in the mix, which as a rule, makes concrete stronger,” he said. “There is also better packing density of the particles, so the resulting concrete has lower porosity and less voids than you’d expect to see.
“Lastly, engineered sand doesn’t have the potential for salt contamination that marine sands have, and which reduces the long-term strength of concrete.”
Kayasand’s manufacturing process is also dust-free, low-noise and uses no water for washing.
Kayasand engineered sand is made to the exact particle size and shape specified, using a process that removes contaminants and blends the product to the desired consistency at the plant prior to delivery.
Kayasand’s manufacturing process is dust-free, low-noise and uses no water for washing.
Images: Kayasand
Concrete made using Kayasand V7 sand was still stronger., despite using 10 per cent less cement.
Jason Chandler, director at Concrete Insights and 21-year veteran of the concrete industry, saw the potential in Kayasand’s technology.
“I’ve been involved with trials that Kayasand have done on Australian source material from across the country, testing the use of its engineered sands in concrete,” he said.
“Kayasand’s product is capable of not just replacing manufactured sand, but also the natural fine sand sourced from dunes and rivers.
“By using this engineered sand, I’ve been able to make concrete with a single source of sand that has an increased strength, reducing the amount of cement required by five to 15 per cent.
“The consistency of the Kayasand product also helps reduce variations in concrete strength. This enables concrete producers to lower their target strengths, which are typically set high to account for these variations. This in turn further reduces the amount of cement needed.”
Chandler set up Concrete Insights in part to help educate the industry about ways the industry could improve its sustainability.
One of the issues that other manufactured sands face is sub-optimal grading or shape, requiring the additional blending of natural sand into a final product.
This has led to the misconception that manufactured sands need to be blended with natural sand.
This is no longer the case – it’s possible to engineer sand to high standard that is fit for purpose.
Chandler said that forwardthinking companies are seriously considering the technology.
“Fine natural sand is increasingly hard to get, meaning you need to find an alternative supply from somewhere. We can’t rely on expanding dredging and mining operations to get more sand, so the Kayasand process makes sense,” he said.
“In my view, at some point the price of carbon will also become more and more critical. Cement is a big driver for carbon, and if you can remove five to 15 per cent
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with engineered sand, the economics will quickly pan out.
“Australia doesn’t currently have a formal price on carbon, but Europe is much further advanced on this. A lot of tier one contractors that work in our infrastructure industry are European and are starting to put pressure on their suppliers, including concrete manufacturers, to actively reduce their carbon emissions.
“In the past, the industry has benefitted from having easy access to plenty of material, but change is afoot, and the industry will need to incorporate innovations like this.” •
For more information, visit kayasand.com
Concrete made using Kayasand V7 sand was still stronger, despite using 10 per cent less cement.
HANDLE THE PRESSURE
Metso’s high-pressure grinding rolls are helping quarries deliver high-quality sand and aggregates to the market.
Access to natural sand reserves has become more complicated in certain regions, and other areas are seeing their reserves become exhausted.
For customers looking to develop highquality sand or work with complex feed materials, Metso has developed the HRC 8 and HRC 800.
Featuring a simple and robust design, the HRC 8 and HRC 800 provide a low cost of operation and improved product shape and grading.
Designed to work in challenging applications, the machines allow operators
to turn waste products into sellable materials. These applications range from feed materials with low crushability to materials with high moisture, including clays, without overloading the crusher.
“These machines are suitable for specific applications where materials that are waste from the crushing and screening process can be reprocessed to obtain good high-quality sellable products. HRC 8 and HRC 800 produce the highest quality products with improved shape and relatively low energy and wear parts consumption with the lowest possible cost per tonne,” Metso said.
At the heart of the design for the HRC 8 and HRC 800 is the high-pressure grinding rolls (HPGR) technology, which is optimised for manufactured sand.
The robust HPGR technology compresses the material between two rotating rollers, one in a fixed position and one in a floating position. Together, the rollers generate a high pressure, which crushes the feed material into the desired size.
The operator can adjust the speed and pressure from the HRC to suit the material conditions and application. The pressure control allows the operator to adjust the reduction ratio, while the speed control ensures the throughput can be tailored to the operation. According to Metso’s internal testing, the HRC 8 and HRC 800 can use up to 50 per cent less power in sand production than other equipment for the same net product.
The industry-tested machines have delivered impressive performance in realworld applications. One Metso customer in Mexico wanted to increase their sand production by repurposing some of their onsite, unsellable waste product.
By re-crushing 19mm and 12mm gravel rock and increasing the asphalt sand fines content to a minimum of 15 per cent, the customer was able to deliver a quality sand product that saved them from buying it from competitors.
The HRC 8 was added to the circuit for a demonstration, using 19mm top rock from their stockpile. The customer was able to adjust the machine parameters to suit their needs. With 60 per cent less than 16 mm on feed, which was very clean with no fines below less than 15 mm, they recirculated +6 to -9 mm rock with an ST 3.8 double-deck screen, which helped to increase sand production.
“HRC 8 process adjustable to customer’s sands needs, quality and production volume, it depends on the combinations
Images:
Metso The HRC 8 features high-pressure grinding rolls.
of the crusher setting parameters. Not too many parameter options can be adjusted to control the ultra-fines production, this characteristic depends more on the feed material properties, but with the wide range of operating pressures, the HRC technology is the best option for those requirements,” Metso said.
This is where the HRC 8 and HRC 800, with their strengths in product shaping, product gradation, and fine production, can play a key role in the production of manufactured sand.
“HRC 8 and HRC 800 deliver a perfectly cubical shape for concrete and asphalt sands,” Metso said.
QUARRY PUMPING EXPERTS
Metso has designed the machines to prioritise safe and easy maintenance to reduce downtime. The patented split shaft in the HRC allows wear parts to be changed easily without disassembling the machine.
The anti-skewing arch frame ensures bearings are protected from misalignment, which saves maintenance time.
This is supported by the Metso global distribution and logistics network, which ensures that its original equipment manufacturer spare and wear parts are available when customers need them. Whether it is a standard or engineered-to-order part, Metso’s network can provide it.
They can be equipped with Metso crusher automation, which controls and monitors the crusher and ancillary equipment via a remote control. The crusher automation is a complete
RETHINKING GRANITE
A family-owned quarry is using innovative practices to meet sand demands in central west NSW through its reserves of decomposed granite.
Bathurst Quarries has supported local campaign-type projects in the region, including roadworks or site developments in Bathurst, since it was first approved in 1997.
But in 2015, the first of three pivotal moments in the family-owned business occurred.
Colin and Mary-Rose Townsend, who owned and operated the quarry, secured state government approval for a 100,000 tonnes per annum extraction limit with a 50year extraction lease.
“That was a huge achievement by my parents to get that. Once that approval had been granted, it was an opportunity to build the business around that,” said Will Townsend, quarry manager at Bathurst Quarries.
The pair still own and operate the business, but in 2017, Will returned to the family business after previously working at Nestlé. While Nestlé is more renowned for confectionary and cereals, Will’s lessons from his previous line of work have been translated to the quarry.
“After they got the approval, I was just trying to help them get things rolling, and ultimately, I ended up leaving my career with Nestlé to go play in the sand pit,” Will told Quarry
“I was really trying to hone in on the systems. We run on the notion that systems run the business and the people run the systems.
“So I am making sure that everything is nice and tidy, from compliance, safety, and reliability [standpoint], that production has a system around it, and that our employees are well-versed in those.”
The third factor was Colin Townsend conducting some small-scale experimentation with the quarry’s preexisting decomposed granite reserve.
He discovered through washing the material through an old Finlay screen and a sand screw that it was possible to create quality washed sand. Local batch plants conducted quality trials of the new material, proving it could be a successful input to their batching.
At first glance, the three moments appear to be unrelated, but each has played a critical role in Bathurst Quarries’ journey to develop manufactured sand.
The Townsend family wanted to transform Bathurst Quarries from a business reliant on campaign projects into one with a consistent business flow throughout the year.
The new extraction limit and the security of the 50-year lease and the discovery of the new manufactured sand made this possible.
While they could have kept selling
decomposed granite as a dry product, they saw an opportunity in the sand market and believed in the quality of their product.
The company noticed that many of the alluvial sand deposits had been diminished in the Central West region of New South Wales. Given that many of the reserves had been exhausted through extraction, this created a void of sand producers within the region.
The success of Colin’s experimentation gave them the spark of an idea.
“That gave us some confidence to ahead and build a fixed plant to make a quality washed sand from our raw material which is the decomposed granite. From a sales stability point of view, that meant we had a nice, even approach to sales day-on-day rather than a project every few months,” Will said.
Will conducted an extensive investigation with his friend Matt Farley, which included 13 sites along the east coast of Australia and sites overseas in China.
The research trip, which saw Will welcomed by IQA members to learn about manufactured sand, played a significant role in Bathurst Quarries’ project. The likes of Hanson, Boral, PF Formation, Pioneer Sands, Walkers and many others opened their doors in a show of generosity Will is thankful for.
Bathurst Quarries features reserves of decomposed granite
“I was just ringing people up and asking to visit … and the quarrying industry is fantastic. They welcomed me in and showed me with pride how they did it, which was fantastic. It had a remarkable influence. Just having exposure to how those sites run was tremendously valuable, and then, to get more detail on how they were washing and dewatering, I just took snippets from everywhere,” Will said.
“With my knowledge of these sites, I had some confidence that we could produce a product. I also went to China and looked at three manufacturers of fixed plants to potentially import and commission on our site. We determined that we could probably build a fit-for-purpose plant economically rather than import.”
However, as a family-owned and operated operation, they needed to manage to build the new fixed plant alongside managing their day-to-day business and existing mobile plant, with the cash flow funding the new project.
Due to this, Bathurst Quarries implemented a three-phase approach to the project, starting with a washing plant and dewatering plant in phase one. The screen enabled the sand fractions to be washed and separated while the sand screws dewatered the material before it was stockpiled via a conveyor.
Through the initial product trials, the company noticed that in trying to obtain a 3–5mm-size product, around 45-55 per cent of the material was yielding pea gravel. The pea gravel was a slow-moving product that was not in high demand and stockpiling it was taking up valuable room on the site.
This led to the second phase, which saw the implementation of a vertical shaft impactor to crush the material down to the
material suitable for sand. The third and final stage was a primary dry screening system, which involved a feed hopper and a large primary screen where oversized material would be shafted back to the VSI crusher.
All the correctly sized material was shafted to the washing and dewatering plant for washing and separating.
“As a small-scale business, we didn’t have a lot of capital or cash flow, so we had to be progressive with how we went about manufacturing new pieces of equipment,” Will said.
“We built all of the fixed plant. It is all-electric, it is all PLC-controlled and it is operated via a tablet in the front-end loader instead of a manned plant room. A big part of our ethos is to produce more with less, so produce more volume with a reduced head count.
“To date, it is working beautifully.”
The project, which took four years to complete, has transformed the familyowned business by adding a new revenue stream while maintaining its values. It was completely built within the on-site workshop by the employees.
“It was a really heavy few years; they were big days for seven days a week. It didn’t stop, but you just accepted it as the norm,” Will said.
“We were so committed, not out of desire or passion but out of absolute necessity. The commitment was absolute from the first purchase order because we had to see it through.”
The largely autonomous plant produces around 100 tonnes per hour, and one employee controls the entire processing operation.
“It is very important for us as a business to be very good at the basics and efficient so we can compete in the market. Being able to do more with less is how we keep going in business,” Will said.
“I believe we’ve established ourselves well within the market now.” • For more information, visit bathurstquarries.au
Bathurst Quarries built its own plant to process the manufactured sand.
FUTURE FOCUSED WITH GLOBAL AMBITIONS
VRX Silica aims to pioneer a new way forward with its silica sand deposits in Western Australia to support development of a growing export industry.
Ideas can come from the strangest places at the most unexpected times.
Bruce Maluish, managing director of VRX Silica, read The Economist in 2017 and was struck by an article that could change the course of silica sand production in Australia. The article indicated that China had made silica sand a strategic mineral, which put it in the same category as uranium and rare earth minerals, which have stringent government controls on production.
“I did a bit of research and discovered at that time, many Asian countries had banned or restricted exports of silica sand. They were all concerned about their own domestic supply,” he told Quarry.
“This was in response to the concern that Asia was starting to run out of silica sand. There were a number of articles being published at the time and when you delve into it, you discover that because of the heavy
demand by the concrete industry, the glass industry was losing access to sand that is able to be beneficiated to the quality to make glass.
“Asia is running out of sand, but it is also happening in Australia. Not so much in Western Australia and Queensland, but New South Wales, Victoria and South Australia are running into serious problems accessing suitable sand they need for concrete.
“The global squeeze in sand supply, particularly in Asia, has seen a steady price increase to the point where it can handle the shipping cost from Australia. Ten years ago, there was a limited export industry, but there is going to be a sand production industry for export from Australia, and it is going to become quite substantial.”
Many countries and their sand dependent industries have found local resources exhausted or becoming severely restricted.
In 2017, Vietnam banned all exports of silica
sand to help preserve existing supplies for its infrastructure projects before lifting it in 2020 with stringent conditions in place for exports. These scenarios create a conundrum as sand dependent industries search for new suppliers that meet their requirements.
Maluish’s research indicated that the trends of global silica sand supply presented a window of opportunity to become a supplier of high-quality sand.
This was the basis for VRX Silica’s idea.
When Maluish started the search for resources, he had four main criteria in mind: the site had to be in Australia, it had to be a granite-based deposit, it had to be near established infrastructure (including road and rail), and it had to be located on crown land.
If the site is on crown land, access to it would require dealing with the state government, but it would negate the need to deal with potentially multiple landowners.
Images: VRX
Silica
A render of the proposed VRX Silica site at Arrowsmith North.
Given the nature of the main applications for silica sand, beach sand and desert sand are both unsuitable sources. Beach sand is predominantly calcium carbonate (shell grit), and desert sands, noted for their rust colouring, tend to be less inert and contain excessive iron.
Maluish found his answer along the Perth plain, which runs from Busselton to Geraldton.
“When I had a look, there were really only two areas that met my criteria, and it had to have those attributes … I started searching, and low and behold, the best location was in our backyard, and we’ve got them both in extensive landholdings at Arrowsmith and nearer to Perth at Muchea,” he said.
Between those two primary silica sand deposits at Arrowsmith North and Muchea and its three other deposits, VRX Silica has a total mineral resource of almost 1.4 billion tonnes. Arrowsmith North and Muchea have been recognised in the initial Australian Critical Minerals Prospectus in 2023 and the subsequent edition in 2024.
Arrowsmith North is on track to be the company’s first operational silica sand mine site, followed by Muchea. Quality testing of Arrowsmith North’s sand has indicated it is suitable for use in the production of automobile glass, flat glass for construction, and container glass. However, as an unexpected bonus for the company, further testing revealed that its sand could meet stringent specifications for high-quality foundry sand.
The foundry market has grown substantially due to improved 3D printing through technology, innovative 3D silica sand printing media and expertise. The technology is now being used in the foundry and casting industries to create highly intricate and complex moulds. Products constructed via 3D printing moulds are used in various industries, including healthcare, aerospace, and construction.
Muchea has an even higher grade of silica sand, which the company expects to be used in producing ultra-clear glass, which is particularly in demand in the solar panel industry.
“What we’ve discovered at Arrowsmith North is we have very high-quality foundry sand, global supplies of which are significantly diminished,” Maluish said.
“The foundry market is a specialised demand and smaller than the glass market. Between sand for flat glass and container glass, Asia uses 140 million tonnes a year with projected
steady growth. The number of industries that are associated with glass sand or foundry sand and the investment in those industries in Asia is huge, with a huge capital investment which is dependent on a reliable supply of silica sand.”
However, VRX Silica has been on a long journey navigating an extensive approvals process towards development of its sites to production. Maluish said the company had experienced a steep learning curve as it learned about the industry, the products made from it, and the potential markets.
The company’s most important learnings were in determining the best processing methods, as they attempted to rewrite the rulebook of conventional sand processing. Conversations with metallurgists with experience in the lithium industry have revealed a new processing path for VRX Silica.
Instead of using the separation methods traditionally seen in the sand industry, the company is embarking on making a customised processing plant that uses a flotation method seen within the lithium industry. Patents for this approach have been applied for in Australia, Malaysia, Vietnam, Japan, Korea and the United States of America.
“There are techniques they use to process lithium that apply to processing silica sand. We can take some pretty ordinary sand and turn it into glass-quality sand using these techniques,” Maluish said.
“None of these techniques are particularly noteworthy, but no one has done it with silica sand and our whole process circuit is different to anybody else’s silica sand processing.”
The inclusion of Arrowsmith North and Muchea in the critical minerals prospectus published by Austrade has driven specific interest in the projects.
Among other inquiries, VRX Silica has been approached by Indian companies for glassmaking and foundry sand and Indonesian, Saudi Arabian, and Chinese companies for glass-making sand.
Two South Korean foundry industry buyers have signed offtake agreements, which would make it the country’s first and only Australian supplier of foundry sand. A Taiwanese glass manufacturer has also signed for offtake, and many others across the Asia Pacific region are also interested.
As a potentially lucrative aside, while looking at potential downstream opportunities, VRX Silica is investigating the production of high-purity quartz (or HPQ) flour at Muchea. The HPQ product is used in the fast-growing LCD production market, which relies on high-quality flour with stringent size specifications. The company is undertaking further metallurgical test work, process circuit design and investigation of potential markets in Australia and internationally.
The Western Australian Government has provided $2 million in matched funding from its Investment Attraction Fund to support the ongoing development of this unique industry.
The Arrowsmith North project is close to receiving the requisite environmental approvals and permitting, and it is likely to be operational relatively soon after.
“It’ll be a six-to-eight-month process to build the plant and, all things being equal, we expect to be in production pretty close to the end of next year,” Maluish said.
It has been a really interesting journey, and I’m thoroughly excited about the next stage as we move through approvals into development and production at Arrowsmith North.” •
For more information, visit vrxsilica.com.au
The company has developed a modified loader bucket to carry out vegetation direct transfer.
MARKING NEW TERRITORY
Territory Sands is backing itself to become one of Australia’s key frac sand quarries. The results could have a significant impact on the natural gas industry.
Territory Sands has embarked on a journey to become a major player in the frac sand industry, which could supply significant gas projects in the Northern Territory.
The company has three frac sand deposits, totalling around 108 million tonnes of sand. Its location means it is within a trucking distance of between 50 and 150 kilometres from most Beetaloo Basin gas wells.
Nigel Doyle, the company’s managing director, sits on the board of Territory Sands alongside Michael Ashton, Stephen Gavin, David D’Astoli and William Riccardi, who serve as non-executive directors. Doyle spoke to Quarry about how the company is ideally poised to support the gas wells in the Beetaloo Sub-Basin.
The Beetaloo Basin is far from a small Northern Territory gas reserve; some experts have pointed to its reserves being “globally significant.”
The Beetaloo Sub-Basin, which is 500 kilometres from Darwin, is estimated to have 500 trillion cubic feet of gas alone within its Velkerri B layer without accounting for other geological layers known to be gas-bearing.
Last year, the Northern Territory Government gave the green light to enable production within the Beetaloo Basin and recently awarded major project status to
Tamboran Resources’ gas project in the area.
“Back in 2019, we realised the potential size of the Beetaloo Basin shale gas resources and identified the need for frac sand to be utilised in the fracture stimulation of these wells. Current estimates are around 11,000 tonnes of sand will be used to frac each gas well,” Doyle told Quarry.
“In America, 80 million tonnes of sand is used each year for fracture stimulation to produce shale oil and gas. We formed a private company in 2019 and were backed by Titeline Drilling out of Ballarat for initial startup funding. Even today, there is no dedicated frac sand quarry in Australia, and frac sand is imported from California and Saudi Arabia.”
In simple terms, to conduct fracking in shale basins like Beetaloo, operators use large volumes of sand and water with high pressure to drill holes that infill and prop open fractures in the target shale formations.
This method creates the required conductivity for oil and gas to flow from the shale to the surface through the permeable sands.
But it is not quite as simple as using any sand available, like beach sand or desert sand.
SiO2 after processing. Its Vermelha Project is estimated to contain 51 million tonnes of frac sand, followed by its Forest Hill South project (36 million tonnes) and Forest Hill North project (20 million tonnes).
The process of hydraulic fracturing has been used globally for more than 60 years in the oil and gas industry. Territory Sands’ research discovered that no frac sand suppliers were known in the Northern Territory, while there were a limited number in Queensland and South Australia.
This created a void in the market, which Territory Sands identified, where Beetaloo Basin projects would have to import frac sand from international or interstate sources.
In comparison, Territory Sands’ sand quarries are within 150 kilometres at most from the Beetaloo Sub-Basin gas wells and between 500 metres and eight kilometres from the Stuart Highway.
The company has undertaken rigorous testing to ensure its product’s quality.
used in hydraulic fracturing.
“The early years went reasonably smoothly. We were able to get on the ground, drill and identify over 100 million tonnes of fine sand on a number of exploration tenements and then apply for quarry leases to secure those resources,” Doyle said.
“Geotechnical testing in Australia and overseas proved the sand to be in spec for use as proppant in fracture stimulation, and the potential quarry locations are adjacent to the Stuart Highway and within trucking distance to the Beetaloo Basin well sites.
“Land access issues and Native Title delays have at times slowed down our journey, but those issues are likely to be felt Australiawide for all operators in the extractive industries. Trying to source ongoing funding for junior explorers and private companies has also been tough over the last year or two.”
The company has also discovered potential silica sand resources in its research from frac sand. Silica sand’s primary uses are in the glass-making and foundry industries, with Asia being the biggest silica sand market in the world. While research companies like IMARC Group have predicted major market growth for silica sands, Doyle said the company’s proximity to the market would make it difficult to pursue it.
“We started off looking for frac sand and then identified potential silica sand resources in the area, and we were able to drill an Inferred Resource of 174 million tonnes of
silica sand that can be processed to a quality suitable for glass making. Our best quality frac sand is around 99.3 per cent SiO2 and suitable for use as foundry sand, although we are too far away from any market for it to be of use,” he said.
“The company also has three quartz tenements within 100km of Darwin Port, with processed quartz once crushed and pulverised to silica sand of 99.85 per cent SiO2 and less than 100ppm Fe2O3, making it suitable for use in solar panel glass. We are looking for investors to fund further exploration and development of these tenements.
“In terms of construction sand, silica sand and foundry sand into the Darwin and export markets, there needs to be both private and government investment in nearby rail infrastructure to make that market a reality. Transport costs by road just don’t make it currently viable. Both Darwin and Katherine will shortly be looking at acute shortages of fine concrete sand due to various government environmental decisions and policies over recent years, and given around 98 per cent of our sand is less than 1mm in size, we will have large resources of natural sand for use in the construction industry and use as thermal sand as the need arises.”
The Northern Territory Government’s recent approval to kickstart production in the Beetaloo Basin follows the Northern Territory Fracking Inquiry, also known as the Pepper Inquiry, which provided 135 recommendations for safe use of onshore fracking.
The overall report concluded that the risks could be mitigated if its recommendations were fully adopted. The NT Government’s adoption of these recommendations paved the way for production in the Beetaloo Basin.
Doyle said providing local fracturing sand could offer significant savings for these companies operating in the Beetaloo Basin.
“In terms of frac sand, Beetaloo gas companies are wasting $5-6 million per well by importing sand rather than using local frac sand, so there is a definite market there,” he said.
“In 2025, we hope to build our first frac sand quarry near the township of Larrimah to supply frac sand to the Beetaloo Basin and fine concrete sand to Katherine. We have a water licence to wash our sand issued by the NT Government with two bores already drilled. We are also perfectly positioned for future sand requirements for the Sun Cable solar project if it comes to fruition.” •
For more information, visit territorysands.com.au
Silica sand’s primary uses are in the glass-making and foundry industries.
IQA CONFERENCE
INNOVATION AND CREATION
Quarry was on the ground at the recent IQA National Conference to find out how the industry is primed to innovate and create for a bright future.
When Adelaide played host to the 64th IQA National Conference earlier this year, it attracted 635 delegates from around Australia and around the world, marking a significant gathering for the quarrying industry. ith 52 speakers, 77 exhibitors, and 16 sponsors, the event demonstrated strong industry engagement and support.
The theme of this year’s conference, ‘Innovate and create’ highlighted new technologies and lessons to improve industry sustainability.
Industry leaders, innovators, politicians and enthusiasts explored the latest trends, technologies and sustainable practices shaping the future of the sector.
Conference chair James Rowe told Quarry he was excited to help showcase an informative and relevant program that would help quarries enhance the way they operate.
“We worked hard on the program to make sure that we aligned with the conference theme of innovate and create,” he said. “And we got really positive feedback from our delegates, which is fantastic.
“We need to keep innovating and creating opportunities for the industry. There’s not a silver bullet, but we continually
need – whether it’s through data analytics automation –to keep the theme of ‘innovate and create’ real.”
Rowe said attendance was up 15 per cent compared on the 2022 IQA National Conference in Newcastle.
“We’ve had really good representation from most states in Australia, and we’ve had some good representation from overseas as well,” he said.
DAY ONE
The proceedings began with a tour to one of the industry’s oldest operations in Adelaide, the Boral Stoneyfell Quarry.
The quarry, which was started in 1837 to supply roadbase and aggregates to the recently-founded city, hosts a Primate Mine 1 – the first tenement to be held in the state. It has been identified as a Strategic Mineral Resource Area as part of the Resource Area Management and Planning project undertaken by the South Australian Government.
Boral Stoneyfell continues to provide high-quality materials into Adelaide and the surrounding areas, while also providing some of the best views over city.
Live crushing and screening were on display,
IQA Award Winners:
Alec Northover Award (sponsored by AIQEF)
Harry Lewis – Neilsen Group
Gold Hard Hat Site Safety Award (sponsored by WEIR)
Caitlin Redding – Hanson
Gold Environment Award (sponsored by Groundwork part of SLR)
Adam Evans – Holcim and Vern Newton
- Hanson
Excellence in Innovation and Community Engagement (sponsored by Eltirus)
Adrian Bull – EB Mawsons
Quarry Manager of the Year (<10 FTE)
Shane Pescud – Hanson Australia
Quarry Manager of the Year (>10 FTE)
Vince Matthews – Gunlake Quarries
Quarry Operator of the Year
Bradley Power – Hallett Group
IQA Conference Exhibitor of the Year Wormald President’s Medal
Greg Dressler – Hanson
IQA Excellence in Leadership (Female)
Jordan Pedley – Barakee Rental
IQA Excellence in Leadership (Female)
Brad Nelson - Hanson
along with information about the ongoing quarry operations and new safety technology.
Later in the evening, attendees were invited to network at the Hitachi Welcome Reception at the National Wine Centre, where outgoing IQA President Duncan Harris officially completed the handover to incoming president Michael Close.
DAY TWO
The second day saw the conference begin in earnest, with South Australian Energy and Mining Minister Tom Koutsantonis welcoming delegates.
Stephen Halmarick, chief economist and global head of economic and markets research from the Commonwealth Bank, followed the welcome and offered key insights into financial futures.
Meanwhile, exhibitors were excited to showcase the latest and greatest technologies, equipment and machinery.
Vital industry topics, such as digital transformation, compliance, safety, and more were discussed by key industry figures and decision-makers.
Attendees were invited to network at the Hitachi welcome reception at the National Wine Centre.
Images: IQA
IQA CONFERENCE
The presentations on day two included the industry leaders’ panel, which saw IQA chief executive officer Jane Schmitt joined by speakers from Holcim Australia, the Hallett Group, Hanson Australia, Adbri, and Boral to discuss innovation and collaboration.
The busy day was followed by the Komatsu conference dinner, where attendees could network and the winners of the IQA Awards were announced.
DAY THREE
The final day of the conference was focused on the future, with a keynote presentation from Claire Madden, a social researcher of generational change on the future of work and how to attract Generation Z to the quarrying industry.
A particular highlight of the third day came when around 60 school students, aged 14–18 visited the conference and were able to chat face-to-face with quarrying experts from across the industry. The IQA Young Members Network shared their experiences
Delegates visited one of the industry’s oldest operations in Adelaide, the Boral Stoneyfell Quarry.
within the industry, including the recent international study tour.
Rowe said the representation of young people at the conference was great to see.
“Hopefully, we can continue to build on that,” he said. “We’ve got a big focus on bringing our younger people into the industry, and I’d love to see more on
“I think the big focus for the next few conferences will be making sure we’re attracting young people to our industry and providing professional development opportunities.”
The event wrapped up with the Caterpillar Gala Dinner, a Moulin Rouge-themed blacktie event, and the Wormald after party.
Each social reception attracted over 400 delegates, highlighting the strong networking component of the conference.
Rowe thanked all of the sponsors, exhibitors, and delegates for attending the conference.
“It’s a big investment and, as a committee, we really value seeing the industry come together,” he said. •
Robust HRC™ high pressure grinding rolls
IQA NEWS
OUT AND ABOUT WITH THE IQA
IQA Cavpower tour
Cavpower opened its doors to a site tour of its facilities located at Gepps Cross in Adelaide, specially arranged for IQA Young Member Network (YMN).
Mark Taylor, the major accounts manager, who has been with the company for over 40 years, led the tour of Cavpower’s multi-million dollar facility showcasing major upgrades and capabilities. This included a new components rebuild centre (CRC), a Parts Distribution Centre, a service operations centre (SOC) and new administration building.
Cavpower, founded in 1972, was a South Australian privately owned company until it was sold to a Malaysian multinational conglomerate ‘Sime Darby’ late last year.
We started the tour viewing the innovative Dematic AutoStore system at work at Cavpower’s advanced parts centre. It uses robots with AI technology to pick parts in column structure housing over 50,000 locations and the capability to pick 140-line items per hour per person. Investing in this innovative solution has helped them reduce their footprint by two-thirds and elevate their customer experience.
Cavpower’s CRC is one of only seven facilities around the world to be a Caterpillar five-star certified facility. The CRC has the capability to service and repair the full Cat product range of major machine components. The state-of-the-art facility consist of 20 bays with the capability to repair and rebuild over 80 individual
components per month, including engines, fuel pumps transmissions, torque converters, differentials, wheel ends, final drives, hydraulic pumps, and motors.
The SOC comprises 26 bays fitted with 12.5 to 25 tonne overhead cranes. The facility hosts general workshop, engineering, welding and fabrication, machine build-up, field service, lube truck and paint shop.
These facilities are further augment by South Australia’s only track press with the capacity to accommodate any machine size up to a Cat D11 Dozer.
During the planning phase of these new facilities, a team was dispatched to the best Caterpillar dealerships both domestically and in the USA to seek out ideas for potential adoption or refinement. A lesser-known detail worth noting is the use of pavers instead of concrete in front of the workshops. This design choice facilitates the manoeuvring of tracked machines, allowing for easier turning. Unlike concrete, if damage occurs, replacing individual pavers is a more cost-effective solution compared to repairing concrete, which would entail significant investment.
The latest addition to the site is a customer experience centre – a showroom space designed to showcase the latest Cat machines, technologies and services. The customer experience centre gives Caterpillar owners and enthusiasts the opportunity to experience the machines and technology up close as well as consult with a Cavpower specialist.
The multi-million dollar investment also prioritised environmental enhancements. This involved the installation of a large water tank beneath the new parking area to capture rainwaters from various buildings, ensuring a self-sufficient water source. Additionally, plans are underway to install solar panels, enabling complete independence from the grid in the future.
Their workshops were impeccably clean and regular workshop and contamination control audits ensure adherence to best standards across all workshop areas.
Cavpower employs over 500 staff members, with more than 250 being industry-leading Cat-certified technicians including diesel mechanics, boiler makers, auto electricians, machinists, and field service technicians. Cavpower are fully engaged with the next generation of fitters, employing over 68 apprentices across the state.
With having workshops in 10 locations across South Australia and at Broken Hill, Cavpower is best suited to offer apprenticeships in their hometowns, instead of them having to move to Adelaide to begin their careers.
The IQA Young Member Network would like to thank Cavpower and especially Mark Taylor for his time in hosting us for a great afternoon.
WIQ fireside chat
On 10 October, the Queensland Branch hosted another Women in Quarrying
The CRC is one of only seven facilities in the world.
Attendees at the WIQ fireside chat.
(WIQ) fireside chat at Oxford 152, Bulimba. This event provided a great opportunity for industry peers to come together over refreshments and engage in discussion.
This session, led by Jenny Krasny and guest speaker Belinda Martin (BHP), allowed participants to connect and network on all things WIQ. Belinda’s previous experience in sand quarries and her recent role as manager, health & safety, and asset technical for BHP Mitsubishi Alliance (BMA) provided a great Q&A conversation.
A big thank you to our WIQ Sponsor, Orana Drill & Blast, for supporting this wonderful event.
Victorian Branch and sub-branch student presentation night
The IQA Victorian Branch and Victorian subbranch student presentation night took place
on Friday 25 October 2024 at the Novotel Melbourne Preston.
This special evening celebrated the academic achievements of the 2023 and 2024 graduates in the extractive industry. Nineteen students received a certificate from the IQA, accompanied by a gift compendium by Kinder Australia, sponsor of the IQA in Victoria.
The keynote address was delivered by the inspiring Rachael Robertson, who shared impactful insights from her experience managing a team and operating a quarry in Antarctica. Rachael’s message resonated deeply with both graduates and attendees alike.
Overall, the event was a wonderful success, recognising the graduates’ hard work and dedication and celebrating their outstanding achievements.•
UPCOMING COURSES AND EVENTS
Slope Stability WorkshopKulnura Dec 28am - 4pm 557 George Downes
Queensland branch & central Queensland sub-branch EOY 2024 dinner meeting Dec 55pm - 8pm
Brisbane Motor Museum | 959 Nudgee Rd, Banyo, Queensland
GEOLOGY TALK powered by CLOTHES, COFFEE AND CEMENT
The industry recently celebrated 200 years since the creation of Portland Cement, but modern research continues to push the boundaries of the cement mix.
Joseph Aspdin may not be the most talked about name in the cement industry now, but the Leeds bricklayer has had a substantial impact for 200 years.
He was a stonemason, bricklayer, and, by virtue of creating Portland cement, an inventor. According to various accounts, Portland cement derived its name from its likeness to Portland stone, extracted from limestone quarried on the Isle of Portland.
For 200 years, Portland cement has been the industry standard, noted for its durability and resilience. Aspdin’s Portland cement was patented in 1824 on October 21, as British Patent 5022, 1824: An improvement in the modes of preparing artificial stone.
While others, like John Smeaton, are credited with creating “hydraulic lime,” Aspdin’s invention created one of the world’s most used building materials.
In 1924, a plaque commemorating the centenary of his discovery recognised Aspdin’s accomplishments, which changed the course of infrastructure.
As the milestone reached 200 years in October, it is interesting that the world is adapting cement to fit into a modern context.
Researchers, including ones in Australia, are reducing the amount of cement in concrete
mixes to reduce carbon emissions. According to various estimates, cement creation accounts for around 7–8 per cent of global emissions. According to Scientific American, one kilogram of cement sends one kilogram of CO2 into the atmosphere.
Researchers have recently been using coffee grounds, Australian calcined clay, and newage additives to reduce the amount of cement in each mix and create low-carbon concrete.
Victoria University has an “upcycled” polyester from a pre-owned high-visibility vest to make low-carbon concrete for new footpaths in Melbourne’s Eastern Freeway upgrade project.
The researchers wanted to reduce the amount of textile waste Australians produce each year, ending in landfills. End-of-life uniforms, like high-visibility vests, account for a large part of this after they become unsafe for workplace usage.
Collaborating with Melbourne-based Assembled Threads, the researchers took almost six months and 15 versions to get the right mix. The researchers needed to balance the correct composite balance within the concrete mix when replacing virgin cement. It has completed a successful test pour and large-scale fire testing.
“This is a fibre that will not break down in the natural environment, so we thought we could capitalise on the strength of it to replace other polluting materials that are traditionally in concrete such as cement,” said Malindu Sandanayake, associate professor at Victoria University.
“Initial testing shows this behaves in the same way as traditional concrete. In fact, trial testing achieved the desired compressive strength earlier than expected. It is as strong, almost more so, than a traditional cement composition. Prolonged monitoring of the test sites will be undertaken post completion of the project.
“We think this is just the beginning of a new approach to greener construction and look forward to finding more ways to challenge traditional building processes.” •
Image: Lakeview
Image:
Victoria University
Victoria University ‘upcycled’ high-visibility vests for their research.
Malindu Sandanayake is an associate professor at Victoria University.
